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 »

Polygon Solutions Inc. continues to expand the variety of rotary broaches it is manufacturing. This gear shaped rotary broach can be used to make holes with the matching form using a lathe or mill. Common methods of hole preparation include using an oversize pilot hole to create individual chips at each tooth, or using small end mills to remove as much material as possible before finishing the hole with the broach and broach brake. Custom rotary broaches fit into Polygon Solution’s standard adjustment free rotary broach holder, or can be made to fit adjustable broach holders. Standard rotary broach dimensions are .500″ shank diameter x 1.75″ length. Swiss broaches have an 8mm diameter shank and 1.25″ overall length. Broach materials include hardened M-2, M-42, PM M-4 or PM T-15. Coatings are also available. Gear shaped rotary broaches are another example of Polygon Solution’s innovative machine tooling. Even when rotary broaching may not seem practical, Polygon has been able to help customers interested in rotary broaching these forms to create custom tooling using multiple roughing and finishing broaches. This method of using multiple broaches mimics the multiple teeth of convention broaches, but can eliminate secondary operations. For more information, please contact sales@polygonsolutions.com, or (239) 628-4800.   Read More »

These customized rotary broaches are used in some really innovative new manufacturing processes. Read More »

Polygon Solution’s innovative rotary broach form drill brings lean manufacturing to hexagon and square hole manufacturing. Fort Myers, FL – Polygon Solution’s Rotary Broach Form Drill is a new tool used to improve manufacturing processes used in rotary broaching. Rotary broaching is a machining technique used to create hexagon and square holes in metals and plastic parts such as custom aerospace fasteners, orthopedic bone screws and hydraulic fittings. The new form drill is used to drill the pilot hole needed before the rotary broach can shape the hole. The form drill is appears to look like a common drill, however three innovative features make it much more valuable. The first feature and most important dimension is the pilot hole diameter. Optimal pilot hole dimensions for rotary broaching are about three percent larger than the flat-to-flat dimensions of the hexagon. (see figure 1) The oversize pilot hole makes individual chips curl into the hole, and reduces the amount of material to be removed when broaching. (see figure 2) The smaller amount of material to be removed also reduces the amount of force required by the machine to push the broach into the hole. The second feature of the form drill is ... Read More »

Polygon Solution’s Letter Broach is a new cutting tool used to create letters or numbers in metal parts. The Letter Broach is used in a rotary broach tool holder and is driven in a rotary motion around a fixed pivot point. This rotary motion reduces wear on the cutting tool, and eliminates secondary operations. Letter Broaches may also improve tooling costs and quality systems. Typical methods of marking parts with letters or numbers include stamping presses, hand punches and automated methods which forcefully press a stamp into the metal part. This new method of marking eliminates the impact of a high powered press or hammer, and gently displaces the material until the desired depth is achieved. The reduced impact will improve life for the cutting tool, tool holder and machine. Using the Letter Broach within the machine eliminates secondary operations and reduces opportunities for operator error. Cost savings can include less machines, manual labor and tooling costs. The Letter Broaches are designed to fit inside most industry standard rotary broaching tool holders. A benefit of using letter marking broaches in modern CNC machines with a tool holder carousel is the opportunity to mark mixed batches of parts. For example, if ... Read More »

This YouTube video shows 10mm hex being machined in Nylon. Typical speeds, feeds and part preparation can be used. Rotary broaching is ideal for aluminum, brass and mild steel but can also be used for various plastic materials and nylon. Read More »

Rotary broaching is fantastic for making small forms like hexagons and squares in soft materials like aluminum, brass and mild steel. However, when it comes to aligning multiple holes using a rotary broaching tool, the operation becomes extremely challenging. Most rotary broach holders have a free turning spindle which does not allow for alignment of the holes. The rotary broaching brake is a new mechanical solution for aligning broached forms in machined products. Polygon Solutions Inc. designed the broaching brake to be used as an attachment to its innovative GT Series rotary broach holder. The brake mounts to the tool holder using set screws. Additional screws are included at the opening of the brake to gently tighten against the spindle. The broach is fastened into the spindle, and must make contact and be aligned at the first hole. When the broach is engaged with the part, the brake is loose enough to allow the spindle to turn without interfering with the broaching operation. Unlike typical rotary broaching operations, turning must stop before removing the broach. When the broach is removed, the brake screws are tight enough to hold the broach’s position until it makes contact with the part at the ... 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 »

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 »