Rotary broaching a 3/8″ Hex in 416SS using a Haas TL-25 lathe and Polygon Solutions GT Rotary Broaching Tool Holder. Read More »

A 3/8″ hex pocket being broached in 6061-T6 on a 1992 Hardinge Conquest 42. Read More »

Rotary broaching is ideal for making small polygon shaped forms in soft metals. Soft metals include brass, aluminum and mild steel. Polygon Solution’s standard catalog includes hex broaches 3/8″ and smaller, and square broaches 8mm and smaller. But what if you need to broach a form larger than these sizes, such as the 3/4″ square shown here? The Solution: Polygon Solutions manufactures rotary broaching tools larger than those found in the standard catalog, however broaching those sizes can be challening and may not be possible.For the best chance at success, consider these tips:1. The chamfer for the hole must be larger than the sharp corners or major diameter.2. The pilot hole should be larger than the flat-to-flat dimension or minor diameter.3. There must be plenty of room in the hole for chips to accumulate.4. The machine must have enough power to feed the tool into the hole. In this example, the 1/2″ shank broach shown here is a 3/4″ square and is fastened in Polygon Solutions GT Series premium rotary broach tool holder. The pilot hole is .835″ diameter. This is about 10% oversize which is ideal when rotary broaching squares. The broach and holder were put into a vertical machining center. Simple ... Read More »

We get a lot of questions about rotary broaching in stainless steel. This video shows broaching of a custom shoulder bolt with a 3/8″ Hex in 416SS. The machine is a Haas TL-25 lathe and uses Polygon Solution’s GT Rotary Broach Tool Holder. Rotary broaching any type of stainless steel can be very challenging, but we have many customers who do it and will do our best to try and help you succeed. Read More »

Polygon Solution’s new GT Series Rotary Broaching Tool Holder was featured at the 2012 Hardinge Machine Technology Show in Elmira, NY in June 2012. The broach holder and broaches are making parts on the GX 1000 Vertical Machining Center. Rotary broaches are ideal for making small internal forms in a variety of metal parts. Broach holders can be used in most turning machines, including lathes, mills, machining centers, screw machines and manual machines. Superior design characteristics ensure Bridgeport 40-taper spindle GX-Series vertical machining centers deliver many years of accurate and reliable machining performance, including on-machine rotary broaching operations. The HMTS show features the industry’s leading brands including Hardinge CNC Lathes, Bridgeport Vertical Machining Centers, Kellenberger and Jones & Shipman Grinding Machines, Hardinge Workholding Solutions & Rotary Products and the Hardinge Turnkey Group. Technology Seminars, factory tours, and product demonstrations take place throughout each day. Read More »

We get a lot of questions about how the broach holder rental program works. It’s quite simple really, you buy the holder for $699, and if you return it within 30 days you get a credit of $599. So, it only costs $100 to use it for the month. This is also good if you’re experimenting in a challenging material and you want to see how rotary broaching will work. The best part of the deal seems to be in the cost, because you are able to use the holder for less than it costs. However, the real value is in the exposure. For instance, you quote a job of 100 parts which requires a 1/4″ hexagon hole in aluminum. The new customer says this should be an ongoing job for a 1,000 parts a month. Without the broach holder, you can’t bid on the job. Let’s say you bid on and win the job, rent the holder, and return it when you’re done. Because you have the exposure with the new customer, when the long term job does come through, you have the best chance of winning it. You can now buy the holder when the job comes in, and use it indefinitely. In fact, since ... Read More »

Polygon Solutions Inc. is among the distinguished list of winning recipients of the eighth annual Manufacturing Leadership 100 Awards.  Polygon Solution’s new Premium Rotary Broach Holder project was selected by Manufacturing Executive, the global community for manufacturing leadership and producer of the Manufacturing Leadership Summit and ML100 Awards program. The Manufacturing Executive portfolio of services (www.manufacturing-executive.com) also includes the Manufacturing Leadership Council and the Manufacturing Executive Leadership Journal.   Read More »

Polygon Solutions Inc. is among the distinguished list of winning recipients of the eighth annual Manufacturing Leadership 100 Awards.  Polygon Solution’s new Premium Rotary Broach Holder project was selected by Manufacturing Executive, the global community for manufacturing leadership and producer of the Manufacturing Leadership Summit and ML100 Awards program. The Manufacturing Executive portfolio of services (www.manufacturing-executive.com) also includes the Manufacturing Leadership Council and the Manufacturing Executive Leadership Journal. Polygon Solutions Inc. is a Florida manufacturer of unique rotary broaching tools for the turning industry. The new Premium Rotary Broach Holder is an adjustment free model, and boasts technological advances in pressure relief technology and maintenance free bearings unlike any other in the marketplace. The popular tool is used to reduce secondary operations when machining hexagon and square holes in precision metal products, and is sold online (www.buybroaches.com). In December 2011, Polygon Solutions Inc. was nominated for the award. An independent judging panel chaired by David R. Brousell, Vice President & Editorial Director, and Jeff Moad, Executive Editor of Manufacturing Executive, reviewed project and individual achievement nominations, and the winners were decided by a panel of qualified judges from various companies and organizations in the manufacturing industry. Polygon Solutions will be ... Read More »

The GT Series Rotary Broach Holder by Polygon Solutions is shown (Gold color) in the ST Lathe at Haas Demo Day 18 in Tampa, FL 2011. The 3/4″ shank on the holder is in a sleeve to fit the 1-1/4″ bore. The sample part made in the machine has a T-20 torx-style hexalobular feature machined using the Polygon Solution holder and standard six-lobe broach. Read More »

Polygon Solutions will soon be adding a new turning product to the catalog; External Rotary Broach Tools. These external rotary broach tools can be used to manufacture external precision forms when machining the ends of turned metal products. Standard external rotary broaches fit into Polygon Solution’s GT Series Rotary Broach Holders. The .500″ broach shank fits into the tool holder spindle, and is fastened into the spindle using a set screw. Polygon’s unique through hole feature in the tool holder insures that no hydraulic pressure will build up inside the broach during the broaching process. Metric and Inch sizes will be available for the external broaches. Standard shapes will include hexagons and squares. Custom size hex and square broaches can also be ordered, along with special forms including serrations, splines and torx style shapes. The external rotary broach is the exact same tools as the external wobble broach. All standard external broaches are made from M-2 high speed steel, but can be ugraded to premium PM M-4, M-42 or PM T-15 tool steel. Coatings and other standard rotary broach options are also available. Read More »