Special Form Rotary Broaches

Custom internal rotary broaches are available to suit a variety of applications. No other company offers as many unique special form rotary broach tools as Polygon Solution. Polygon Solutions simply asks you to fill one of our forms or send in your requirements. You can fax, email or deliver a drawing or sample to us for a quote.

Some common special broaches include Serration, Spline, Involute Spline, Double Hex, Double D, Double Square, Double Keyway, Missing Teeth, Spun Ground, Rectangle, Triangle, Letter and Number.

Serrations are commonly found at the end of shafts, as internal or external knurls, and locking features for fasteners or washers. Many serration forms can be made using rotary broaching tools in a lathe, mill or turning machine.
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Spline and involute spline rotary broach shapes are popular forms used for connecting driven components in machines and vehicles. Typical examples would include gear shifters on motorcycles and clamps for engine shafts.
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Involute Spline rotary broach tools can be made to international standards or custom made to your specifications. Typical examples would include clamps for engine shafts and gear shifters on motorcycles.
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Double hexagon rotary broach shapes are popular forms used for driving a fastener with a hex key or socket bit. Typical examples would include custom screws and shaft extensions. Hex keys can be used in more positions with a double hex hole.
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Double square rotary broach shapes are popular forms used for driving a custom made socket with a socket wrench. Typical examples would include sockets made for deep distances or custom forms. Square drivers can be used in more positions.
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ā€˜Dā€™ and Double ā€˜Dā€™ rotary broach shapes are popular forms used for creating holes to connect shafts. Typical examples would include motor driven shafts or door handle hardware. The flat can easily be added to the end of a shaft.
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Custom rotary broaches can be made for creating keyways in small diameters under one inch in length. Hubs and connectors for various shafts often require keyways, and broaching them on your turning machine will often same time & money.
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Special spline and serrated forms with missing teeth can be formed with rotary broaching tools. The process is the same as broaching involute spline. Precision machined holes with a missing tooth are common in connectors and fittings.
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Trying to grind individual radii on the corners of hexagon and square rotary broaches is not always practical, but the spun ground diameter is often an acceptable alternative. This small reduction often saves cycle time and money.
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Rectangle forms are common in manufacturing pockets, slots and clearance holes. The problem many machinists face is creating the form with sharp corners. Many small, sharp cornered rectangles can be formed with rotary broaching.
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Using the Letter Broach within the machine eliminates secondary operations and reduces opportunities for operator error. Cost savings can include fewer machines, less scrap, less labor and reduced tooling costs.
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Triangle forms are becoming more popular and can be manufactured using rotary broaching. Design considerations should include an oversize pilot hole, and room for chips. Triangle broaches are ideal for small, shallow forms.
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We can manufacture almost any form per your print or specifications. We also offer reverse-engineering services and can produce a rotary broach from your part.

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