Hex broaches are specialized tooling used to cut hex-shaped holes. They are designed to cut materials up to 50 HRC. These tools are also easier to handle. Read on to learn more about these tools and how to use them in your shop. You can also download a free CAD file to learn more. This article will discuss the types of hexagonal broaches and how they work. Also, learn more about their benefits and disadvantages.
Hexagonal broaches are used to cut hex-shaped holes
Hex broaches are rotary punch tools to cut hex-shaped holes in various metal products. These tools are often used with a hydraulic press or arbor press. They are designed for precision cutting of hex-shaped holes in one pass and have ample rigidity and cutting range. Hex-shaped broaches are available in both imperial and metric sizes.
Beginners can use a rotary broach to make hex-shaped holes in simple metals such as steel, aluminum, brass, and copper. The tool is relatively simple and easy to use, but it is important to use it correctly to ensure accuracy. Hexagonal broaches require a broach holder, a small V-block that sits on a spindle on a metalworking machine.
A rotary hex broach has a holder that revolves around the spindle of a lathe or machining center. The cut part is rotated synchronously with the tool, so the whole process only takes a few seconds. This technique allows the user to produce a complete part in a single setup. In addition to this, it also helps cut a wide range of materials, such as metal.
They can cut materials with a hardness of up to 50 HRC
Rotary hex broaches, also known as hex or wobble broaches, are specialized tools that can be ground to fit specific applications. In addition to the ground hex shape, rotary broaches feature an offset of one degree along the longitudinal axis, enabling them to cut materials with up to 50 HRC. These tools can be ground to a lower hardness than the target material for more complex applications, allowing for faster production.
These tools are available in various diameters and lengths and can be coated for improved performance. Some of the more common materials cut with a rotary broach include brass, stainless steel, and carbon steel. They can also be used for various applications in material science, tool design, and CNC sharpening. Listed below are some applications of rotary broaches.
They require a chamfer
Hexagonal broaches require chamfering at the hole periphery to start. The pilot hole is larger than the broached form to prevent excessive pressure and ensure tool life. It’s also important to make the pilot hole deeper than the broached form, leaving enough space for the chips to collect. Some applications allow the chips to remain in the hole bottom, such as rotary broaching a hexagon fastener.
The hole must be prepared with a chamfer of 60-90 degrees. The chamfer will keep the proposal from turning in the wrong direction. Generally, internal broaching holes should be one percent larger than the material’s “Across Flats” dimension. The size of the pilot hole may be reduced or increased as machinability decreases. Hex broaches typically require a chamfer of about 3%, although the exact size is up to the maker.
They are easier to handle
Both hexagonal and linear broaches are used to cut holes in metal. While both have similar shapes, linear broaches are generally easier to handle because they can be handled from the side. On the other hand, hexagonal broaches are easier to use and have wider across points. That means they are better suited for various applications, including enlarging irregular shapes.
The ANSI standard allows for up to 20 percent flat removal with the start drill. However, print specs allow up to 33 percent witness marks to reduce the cutting force required to broach a hexagonal hole. In both cases, the formula for the start drill is 1.0184 x A/F for squares and 1.054 x A/F for a hex broach.
Another type of broach is called a rotary hex broach. These broaches feature a rotating spindle and can be held on CNC machines, milling machines, screw machines, and manual turning devices. This broach is easier to handle and is better suited for precision work, where precise geometry is important. However, if you cannot get the desired result with a keyway, you can use a rotary broach instead.