πŸ’ Keyway Cutting and Broaching Options: Keyseating, Broaching and more

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Keyway Cutting Tool. Produce your own internal keyways with this easy to use POLIKEY system. Able to cut standard keyways from 3mm to 14mm widths and up.


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How to make KEYWAY on the LATHE

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Internal Keyway Cutting. When your product requires Internal Keyways, such as in Couplings, Hollow Shafts, Rotors and other Power Transmitting Components.


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Making a Keyway Cutting Tool for the Shaper

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KEYWAY MILLING Keyways are grooves of different shapes cut along the axis of the cylindrical surface of shafts, into which keys are fitted to provide a positive.


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SNNC 157 P1 Manual Key Way Cutting

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KEYWAY MILLING Keyways are grooves of different shapes cut along the axis of the cylindrical surface of shafts, into which keys are fitted to provide a positive.


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Cutting a Keyway in a Motor Pulley Using a Lathe

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Minute Man broaches from duMONT accept keyway inserts, as well as slotting and special inserts, for application on CNC lathes and machining.


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No. 1 - Cutting Keyways - 1941

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Internal Keyway Cutting. When your product requires Internal Keyways, such as in Couplings, Hollow Shafts, Rotors and other Power Transmitting Components.


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IN THE WORKSHOP - CUTTING A KEYWAY WITHOUT A KEYWAY BROACH

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KEYWAY MILLING Keyways are grooves of different shapes cut along the axis of the cylindrical surface of shafts, into which keys are fitted to provide a positive.


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Diamond Grinder Part 4: CNC Broaching a Keyway

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Internal Keyway Cutting. When your product requires Internal Keyways, such as in Couplings, Hollow Shafts, Rotors and other Power Transmitting Components.


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Broaching - Cutting a Keyway

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Keyway Cutting Tool. Produce your own internal keyways with this easy to use POLIKEY system. Able to cut standard keyways from 3mm to 14mm widths and up.


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Keyway Cutting Tool For Lathe

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MACHINE SHOP TIPS #151 Cutting a Keyway on the Lathe - a new ''abroach" tubalcain

When broaching on a lathe, the workpiece is positioned horizontally and gravity causes chips to fall down and away. Sanieski added that the broaching system is not only suitable for generating keyways but also splines, squares, hexes and other internal and external features. The challenge when applying this type of tool is that if a user cuts a blind keyway, simply retracts the tool from the cut and then continues to broach, the chips continue to build up at the bottom of the keyway and the insert inevitably becomes damaged, Sanieski explained. Alan Richter. The insert was relatively fresh, with its coating still intact, so Odekirk said he examined the coolant line. Ron Odekirk, production manager for Muthig Industries Inc. The duMONT sharpening stem holds an insert securely in place as the cutting edge of the insert is resharpened at its original angle. Broaching is a very shocking operation. Need for Speed Gardner compares blind-keyway broaching with an indexable-insert tool on a CNC machine to chopping down a tree with an ax. LLC www. The duMONT Minute Man tooling system allows users to broach through and blind keyways, keyways in a tapered bore and shaped or splined holes. Therefore, the company provides a CNC program with its keyway broaching system that promotes continuous tool movement and cutting while eliminating the need to manually clear chips. Gardner compares blind-keyway broaching with an indexable-insert tool on a CNC machine to chopping down a tree with an ax. The types include cross-hole top , groove middle and notch bottom. Coolant was flowing through an ER32 collet, but spraying along the length of the tool without a clearly defined coolant jet directed at the chip. Image courtesy of duMONT. Related Glossary Terms boring boring bar broach broaching broaching machine centers collet computer numerical control CNC coolant cutting force cutting speed depth of cut endmill family of parts gang cutting milling, slitting grinding grinding wheel hardness inches per minute ipm lathe lubricity machining center milling milling machine mill milling machine mill 2 relief shank shaping slotting titanium nitride TiN toolpath, cutter path. In addition, Odekirk explained that he examined where the broach was stopping within the cross-hole and determined that a chip breaks out of the hole at 1. Inserts from CNC Broach, which come coated with TiN, can also be resharpened, sometimes up to nine times, and most of its customers do not recoat them after resharpening, Gardner said. Muthig Industries Inc. CNC Broach Tool offers indexable-insert tools for broaching blind keyways. The company did and produced five samples of each part, which the customer approved, without any issues, according to Odekirk. If the relief area is not large enough, the tool will pound into those packaged chips and potentially cause a crash, he said, adding that coolant flushes the chips right through a cross-hole and avoids that. Gardner suggested that maybe a chip was sticking to the end of the insert, causing the insert to pop out. To achieve the most-effective cutting speed, Gardner suggests holding the broach body in an ER collet with the backstop held directly in a CAT 40 or 50 spindle. Whichever approach is most economical, Gardner emphasized the need to make a mental leap when it comes to broaching on CNC lathes and mills. Cutting Tool Engineering. With a mill, Gardner recommends creating a cross-hole, groove or notch relief in the partβ€”an open area to push the chips into. Author :. This design protects the machine if the insert, which has two cutting edges, experiences a lot of pushback or chips buildup in the relief area, he said. The tools have setscrews on the side, but the inserts are open face. Odekirk added that Muthig also increased coolant concentration to enhance its lubricity and antiweld characteristics. It significantly increases the cutting load. Cutting Tools. It holds an insert at the correct angleβ€”the angle of the face originally ground into the insert. Muthig began single-point shaping with CNC Broach indexable-insert broaches after it quoted producing the crank adapters complete in the lathe without manually loading parts into the machine. The OEM, which had been producing the adapters in-house, turned the parts in a lathe and then moved them to a vertical machining center for broaching, he noted. Broaching a blind keyway with an inserted tool. See sidebar below. One effective method is to use broaches that accept inserts, and the toolmaker offers those in its Minute Man line for application on CNC lathes and machining centers. There is virtually no force involved. LLC, Greenfield, Mass.

Being able to broach a blind keyway while keeping the part on the same CNC machine tool used to perform the other machining operations provides a significant improvement in setup, reliability and accuracy, compared to moving the part to a dedicated broaching machine.

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For shops that resharpen their inserts in-house, duMONT offers an accessory called a sharpening stem. You could push that through with your hand. When blind-keyway broaching, CNC Broach Tool recommends creating a relief area in the part to push chips into and prevent chip packing. The company states that it designed the insert to pop out of the tool pocket to protect the machine spindle if there is not enough relief space. Search form Search. After each "full, hard crash," the machine was out of alignment, which required half a day to correct, he added. With those corrective measures in place, Odekirk said Muthig Industries continues to apply the broaches from CNC Broach Tools to produce crank adapters and has not experienced any crashes or other issues. Odekirk thought that scenario would be difficult to verify, but, sure enough, one day he was watching the machine when broaching suddenly stopped. To break the chips and prevent them from packing at the end of the blind keyway, Muthig machines a cross-hole relief in each part, which is more suitable for this particular family of parts because adding a groove or notch relief would create a thinner wall that could reduce part strength. Not so when broaching on a mill. He recommends to never hold the shank of the ER collet in a VDI boring bar sleeve to avoid generating taper in the ceiling of the keyway. A chip became welded to an insert during blind-keyway broaching at Muthig Industries.