Spare Parts #13 - Making A Square Broach
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- เผยแพร่เมื่อ 28 ก.ย. 2024
- Making A Square Broach, by Clickspring.
It's not necessarily a common event, but when you need to make a square hole, it can be difficult to get a precise result. One of the best methods to achieve a professional cut is to use a custom made broach, so in this video I go through the process of making one from scratch.
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A very special thank you to patron Dan Keen.
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Cameras used in this video:
Panasonic GH5 - amzn.to/2rEzhh2
Panasonic X920 - amzn.to/2wzxxdT
Tools & Shop Products:
"Solidworks 2013 Bible": amzn.to/2FObS1D
"Hardening, Tempering and Heat Treatment (Workshop Practice Series)" - amzn.to/2KbZo6l
Sherline Lathe: amzn.to/2pnXM19
Sherline WW collets: amzn.to/2FYZ7F8
Heavy Duty Arbor Press: amzn.to/2G4gog7
Generic Dial Indicator 0.001": amzn.to/2FOFTyF
Norton 1-by-2-by-8-Inch Fine/Coarse India Combination Oilstone, Red: amzn.to/2tTEPb0
Kaowool 24" X 12" X 1" 2400 F Ceramic Fiber Insulation: amzn.to/2pfsM3d
Abbreviated Transcript:
00:06 No matter what your style of metal working project might be, every now and then there's a need to form a precise square hole.
00:21 A pilot hole locates the exact position of the desired square, and then the broach is forced through the workpiece.
00:53 And that's because, all of the teeth prior to the last tooth collectively prepare the opening for the final tooth to set the dimension, so within reason, we can tolerate some small errors in those teeth, providing that the very last one is correct.
01:26 Its much too long and slender to be turned between centers, so I'll need to form the features by incrementally extending the work from a 4 jaw chuck. And the other key feature is the pilot diameter, which must be centered on the square, so I'm taking care to center the raw stock prior to forming that cylindrical shape.
01:48 I have the work reasonably well centered to begin with, so that when I position the dial indicator, the error that I see for each jaw is quite small I then use 2 chuck keys in opposition to each other, to move the work, so that the dial reads directly between the original 2 readings for both jaws.
02:13 Once its close, I move the zero reference to that point, so that becomes my target when I start to center the other two jaws. Once the work gets close to being centered, the errors start to sit nicely either side of that zero reference, and it gets easier to pull it into position.
02:53 But even doing this quickly, you can see that it will take a fair amount of time to do this for every cut, so there's a strong incentive to bypass this centering process if we can. For now though, the work is centered, so I can make a start on cutting that pilot diameter.
03:39 Next I'm using the first groove position to register the tool after extending the work, and then I'm using the hand wheels to advance the tool the required amount to form the next groove. Now inevitably I will have introduced a small eccentricity to each of these cuts, and the teeth won't be precisely spaced either. But as I mentioned before, they don't really need to be.
04:14 Providing I don't introduce any gross errors, It's close enough for the final result, and by accepting a small error, I can move through this part of the process very quickly.
05:14 The total amount of metal to be removed, is determined by the difference between the pilot diameter and the diameter of the circle that just encloses the final square. That metal removal must now be shared across all of the teeth, so it determines how much I feed out before cutting each tooth, and that in turn ends up determining the broach depth of cut.
05:32 The diameter difference also gives an indication of how many teeth are required to keep the chip load manageable.
06:15 At this point all of the features of the broach have been formed, so it can now be quench hardened, and on this occasion I'm using the tray that I recently made for the current clock project.
07:07 In an industrial setting a broach is far more likely to be pulled through the work rather than pushed like this, and there's a real risk of fracture using an arbor press in this way, so be sure to take it carefully.
07:19 Make sure the broach is perfectly vertical before you push it through, and as always have your eye protection on. But even with all of the compromises, its still a great way to use home shop tools to quickly shape a precise square hole.
Making A Square Broach, by Clickspring.
I have no intention on ever making a broach or even have the need for one and I still watched this all the way through. Amazing production. Everything about this video was in perfect detail it seemed.
Of all the videos I watch - your dominate in: Interest, Delivery, Production. You have it nailed.
+Daniel Wahl Thank you very much Daniel, I very much appreciate your support :)
I love that every little piece you make feels like its own project. When I make things, I always look at the project as a whole. This video showed me that even one small piece of that project should be a project in itself and care should be taken for every little piece. Your work is always impressive. Thanks for the video.
+Ty Mansfield Great to have you watching Ty :)
Good point 👍
There's something very satisfying about watching the broach work through that sheet in the final shots and making that perfectly shaped hole; thanks for the video!
Clickspring, the only channel I always click like before even watching the video, a guaranteed quality and informative production. Always a pleasure to watch you work.
+Jim Brockie Terrific to hear that Jim, very much appreciate your support :)
I have no idea why I needed this information but I don't feel disappointed at all. Now I know how to make a square hole.
Never mind the tool porn or the actual results (both of which are just brilliant), your explanation of the path to the result always makes watching your channel worthwhile, Chris. Thank you. Greetings from sunny Adelaide!
+greaser5691 Cheers Greaser, great to have you watching, right back at you from humid Cairns :)
Who can actually dislike clicksprings videos? This content is top notch and fun to watch
Tool maker,Clock maker,Film maker, Narrator. Wow, thanks Chris keep 'em coming!
These videos are never boring. Well sometimes they are but boring in the right way.
This continues to be a highly professional and fascinating series. You make these intricate processes seem effortless. I can't wait to see your clock project finished.
+Adam Ward Me too! New clock episode in the works, should be out in a little over a week, thanks for watching Adam
What an awesome job. The quality of the footage is equally impressive!
why do i watch these videos? i don't do any metalworks myself and still i can't stop watching...
maybe you like the ironside of the man?
why do people watch sports or Olympic competition. People enjoy watching expertise.
Me too. I love great craftmanship. Check out Oxtools too and also Keith Fenner.
.....
Clickspring, you have to be an exceptional man of many talents, your talents impress me as I think I could be, being able to be as precise as you are working on the small scale as you do. If I could get close to your knowledge and ability I'd be a happy camper..... Thanks for sharing your many videos.....
I like commercially available tooling but there is just something more satisfying in making and using your own. Great video.
+comictrio So true, and a real money saver too, thanks for watching :)
Chris, I've been following you for months. Every single time I pull up TH-cam and you have a new video pop up, it's the first thing I click on. I can honestly say I've never been disappointed with any of your videos (and I've watched them all). Keep up the good work, looking forward to the finished project!
+JaredC87 Cheers Jared, terrific to have your support :)
I must confess, when I watch your videos I feel so calm! Just watching this things getting incredibly done it's like therapy. Your videos are amazing. I don't know if it's only me lol.
+Felipe Wosniak Very pleased you're enjoying the videos Felipe :)
That tiny little lathe is adorable. Looks like a great one to start with in case you don't know if you'll like the hobby, though.
yes I agree, a perfect starting point, thanks for watching mate :)
i need to get my hands on some milling equipment. these videos set fire to my imagination.
a couple weeks ago i made a wooden version of the wheel depthing tool thanks to your video. mine is not nearly as fancy or as accurate, but my substrate is wood, so i have a lot more margin of error.
thumbs up yet again!
+KingTesticus Yes you do! Cheers KT, thanks for watching :)
I'm impressed. That doesn't happen too often. Good job. I am a ex machinist. I do Solidworks design and CNC programming now. Well, I am unemployed but that's what I have done lately. I always believed machining is a lot of common sense and a little luck. You have both. Thanks for sharing the video. I like it.
I know this is an old video now, but just saw it. Very well done. Very good quality and sensible for home shop. I've made and modified broaches when I worked as a toolmaker. Have you considered after plunging the spacing cuts to swivel your compound to form an angle on the broach tooth face? I don't remember exact angles but I think 5-10 degrees would do. The gullet should have a small radius in it, maybe about 1/2 the depth so a grooving tool with radius should work. It will give you a sharper cutting edge angle and better chip formation, curling nicely. Also have you used a cat head on a steady rest along with a tailstock center? That should allow you to cut more teeth in one set up. Nicely done sir, I like your bench lathe. Good tip on the Boric acid
This video have very smooth frames & great lighting. The details are perfect perfect. Beautiful broach. Thanks for shareing.
I didn't knew this tool existed, it's very clever !
Great job Chris !
broaches are how keyways are cut in Internal Diameters.
most. but not all
Just stumble on your videos. Good education for me just starting out with a new mill and lathe! Thank you for a quality presentation.
As always your incredible quality of work and fantastic cinematography make for a wonderful and informative watch. Seeing a video of yours popup on my feed is an awesome moment , It's neat how much work you put into your videos and into the projects themselves, crazy fine work.
Cheers
+Marco Seifert-Simpson Thank you for the kind words Marco, very pleased to have your support :)
Nice to see you have the tools to broach a subject.
+Andrew Tubbiolo You can pick up a one ton arbor press for around $100, way more than what you need for a hobbyist.
Amazing work! I was in a shop when someone didn't have their broach perpendicular and the press made that thing explode like a shotgun! Made everyone jump.
I've been watching a lot of videos about square holes on youtube and this is the best way ! best method！！！！！！！
How is every bit of kit you use always so clean? Amazing. Great vids. Very enjoyable.
Very informative ! You should perhaps mention that when quenching, the broach should enter the water exactly vertically to prevent warping, or ending up banana shaped. This is a very useful tool to have, and saves a lot of fileing.I think the sub titles are an excellent idea.
+Englishman French Cheers EF, thanks for watching :)
You produce some of the best filmed and narrated videos I have seen so far. You have achieved black belt status! Keep up the good work. By the way-- where are you located?
Australia, great to have you watching mate :)
Amazing how often one ends up making their own tools for metal & wood work. Very nice.
+Doug Bourdo So true! Thanks for watching Doug
Might I suggest turning the last 14 mm or so round so your broach falls out easily.
+pdgeman Yes good idea, will keep in mind for future, thank you for suggesting
Beating a dead horse after 7 years, but wouldn't the long square end help to brandish the square hole?
These videos are awesome! I watched the clock compilation and wow! Well done, it keeps people come back for more.
The quality from production to even the tool is better than most big companies even got, this is incredibly awesome! keep it up man.
+Kim Melin Cheers Kim, appreciate your encouragement
That two chuck key technique for the four-jaw chuck is great!
When tools are invented to create tools invented to create tools. Fascinating, thank you!
Master of his craft.
Liked the presentation. A practical, step to next step, approach.
As always, excellent video. Compliments again, Chris, and looking forward to your next video already!
+Tweakwood Cheers mate, new clock episode in the works soon :)
Chris , all the work you do is beautiful ! It’s like the Hallmark Channel for machinist . Thanks for another great video !
These are so satisfying
Very nice video, and seems like an easy build. I like the approach on cutting the graduations on the lathe. I saw a video of someone using a steel tube to put around the broach while it is being pressed through the work to give a little bit more safety to the operator. This will be great for making a square hole for a boring bar, and I will certainly give it a shot.
Chris is an artist!
TH-cam recommendation algorithm at its finest
I've often seen your Sherline as a higher quality version of my Unimat... I love that keyway you have for holding you headstock in normal "straight mode"... I've just got a little locating pin which works more or less but, well, nice bit of keysteel always helps doesn't it.
Shortcuts? ..... you don't seem the guy that makes shortcuts, awesome vid
The lat tme I made a shop made broach was probably 20+ years ago. Only that one was an involute spline broach for cleaning up damaged internal splines. These types of internal splines are normally cut either with Gear Shaper, a Rotary Broach or a Pull Broach on an Oil Gear type of broaching machine.
a great easy way to make a broach. my old company used broahes to form the fir tree shapes to attack steam turbine blades to the shaft.
+Mark Gray Thanks for tuning in each release Mark, I appreciate it :)
EXCELLENT Video as always !
Can't help but wonder about the mentality of the 4 people that gave it a 'thumbs down' ???
+oldSawyer
Seems we are currently up to 13 arseholes. It always baffles me too. :/
shoot there are26 idiots now , this is a very informative video and good as well , not to mention the time he took to make it show how one is able to create art for tools 👍
Wow ! . . . Up to 228 Negative Nellies now as of 9-22-18
oldSawyer 229/17k 229 is not worth the ink to wright this down
LOL. . . Seriously ? . . INK on a Computer ? . . Like in the "Dumb Blonde" Joke about how can you tell which computer belongs to the Blonde ? . . . It's The One covered with White-Out !
I get so excited when i see a new Clickspring video.
+Alex Catto Awesome to hear that Alex, thanks for tuning in each release :)
Yeah, your videos are the best. You must put so much work into them. 👍
have you done a video to introduce us to your machine shop tools and tooling? I was a bit surprised with your laith today when you removed the jaws and drive motor, removed a key and then set the assembly back at an angle..
+Paul Gdry Will do a shop tour at some point, in the meantime: www.clickspringprojects.com/blog/from-little-things thanks for watching Paul :)
Another great video. I needed to make a broach and it's been a long time since I last made one. This video was a big help. Thanks!
Terrific to hear that Frank - you've been a huge help to me over the years :)
can you comment about your boric acid mixture?
Sure Nathan - powdered boric acid you can usually get from the hardware store as a roach bait. Mix it with denatured alcohol to form a thick paste. Liberally coat the part to be heated, enough to ensure that it will cover the part once molten. Once the mix melts, it forms a protective glaze over the part, almost completely eliminating oxidation. Once quench is complete, wash off the boric acid residue with boiling water. IMHO, without doubt the most effective heat treating oxidation protection there is for the home shop. Thanks for watching and asking :)
Thanks for the info. Your a life saver
@@Clickspring So just straightforward water quench? Fantastic video, I can't wait to make one. Thanks a million.
Pyro Doll I think he meant to quench the piece in oil, and only use water after that to wash away the borax glaze 🙂
You can also use Silver Solder flux to prevent oxidisation.
You are always such an inspiration, as much as i would love to use my mill and lathe too busy with the guitars and CAD..... I was one of your first subscriber... So happy to see oh well you did, still need to build an assemble my die filler al the best Thomas
Cheers mate :)
at first a tought it will be boring and nonsense... but you make it so didatic and well elaborated what makes me watch everything and say "whut? already ended?"
Very well done dude. SUB!
Terrific to have you watching mate :)
I can't help but envy how tidy and organised your workshop looks. I'm such a slob haha
Hi,
Just wanted to say I love your videos. Your video style and format is addictive to someone who loves watching machine tools run and how others work. I noticed that sometimes your finish on Cold Rolled steel straight from the lathe tool is a bit fuzzy and I was having problems getting a good finish myself until I stumbled upon a shear cutting tool bit. They are very easy to grind from HSS and put a finish on parts that almost looks ground. They require a very light cut in the range of .003 -.005 thou max and a moderate speed with slow feed. I found they allow me to sneak up on dimensions very easily as well. I just do my turning with a standard lathe tool and leave the part about .010 over size then switch to the shear cutting bit and finish my part of for a very nice finish. It even works really well on hot rolled which can be a turd to be a good finish on. One of the nice things about it is that getting to tool on center height doesn't matter, you can even raise and lower to get to a sharper unused part of the tool before touching it up.
Watching your videos is making me want to buy a small mill and lather and start messing around in my garage.
I'm in awe of you.
Did my apprenticeship making broaches...NAILED IT!
+Tim Cottrell Cheers Tim!
I must do this thanks!
Great video. Thanks for calling out the exact temper for broaches of this type (medium straw). I always enjoy your videos, both the project videos and the tool-making videos. I expect that on a conventional lathe the compound could be set to 3˚ since the headstock cannot usually be rotated. Then the cross slide can be advanced for depth and the compound used for feed.
+Peter W. Meek Awesome to have your ongoing support peter, Cheers :)
The machine porn here is absolutely scandalous.
+_Myst Not gonna lie, it's seriously hot.
+InstrucTube well he didn't use any coolant.
+Jttv Dryair?
+_Myst True.
But he used lotsa lube :J
I don't know anything about making tools but this video so relaxing to watch! :)
This is a great YT! So informative and helpful. I was really interested in your heat treating method. I have always hated the clean up required after heat treating. I don’t know why I didn’t think of covering the item in boric acid or borax. What a simple solution. Thank you. Subscribing, now. And easy decision.
I WANT MORE! MORE! MORE!
I can't get enough of your videos. You're very talented.
I'm pretty sure you're actually The Doctor, and you're really taking us through making our first TARDIS. But either way, it's interesting as all hell. Thanks Chris!
Now thats a skookum choocher
So glad to see another AvE fan over here
+Silverblood13 me too
I'm always impressed with your production quality. Great job
The issue has been squarely broached.
Слава Богу, ты частее выкладываешь видео! Спасибо!
Your videos are absolutely amazing. The videos quality is just awesome, and your explanation is so clear. Thank you for sharing these things with us. Greetings from Hungary.
I have never seen a smaller lathe before.
very nice thank you for ever expanding my view of what can be done with shop made tooling
lol... I see, they’re “shop made”!
Here I was looking all over the internet for a Shop Made Outside chamfer tool....
Thanks for all the fine work Chris! Great lighting & camera work on this one!! ~PJ
+pjsalchemy Thank you PJ :)
What would really be neat is a short tour of your shop. Show off some the machinery and brief description of each.
Chris, as a metallurgist, I was very pleased to see your care while heat treating, especially in regards to oxidation when austenitizing steel. I just would like to suggest that, when using bulky trays like this one to hold the boric acid (clever idea), bear in mind that the mass of the tray might reduce too much your heat flow (quench speed) and therefore the final hardness of the tool. That is also influenced by your oil temperature and viscosity. A cutting tool like this broach will last several hundred times more in 62 HRC (Rockwell C) other than 54 HRC. The file test is nice and useful, but being qualitative, it will never tell you the difference.
Finally, please let us know the song or music name in the video's description. I see several people in all of your videos asking the very same question.
Kind regards!
Marcelo
+MMorenoBrazil Yes agreed, I also thought the same thing. In fact I was also expecting some distortion due to the differential quench, but was pleasantly surprised that it was minimal. Regarding the file test, it is intended as a quick qualitative check to confirm hardening has occured, rather than any sort of quantitative assessment of actual hardness. Same applies to using the oxide colors for tempering. Both are very crude methods, but very cheap and effective. Natuarally, the actual hardness will not be as consistent compared to using pro heat treating equipment, nor will actual HRC ever be known without a Rockwell tester, but it in the home shop setting it matters little. Thanks for watching
+Clickspring Thanks for quickly replying Chris. Yes, they are simple but effective methods! Using a magnet is also useful, as austenite is non-magnetic, so when the heated part does not stick to a magnet, it is time to quench. I am sure you know that trick.
Now, may I know what's the song name for this video? Thanks a lot!
Another awesome video! Thanks for all your hard work creating cool and informative videos. I am always so excited whenever I see that you have posted a new one.
+MoD_Eagle Cheers mate, great to have you watching
fantastic video on the broach Chris,Always enjoy the Step by Step procedures on You,re tool making,thanks for Sharing
+TIM WILSON Cheers Tim :)
OK, we got a square peg, now who has a round hole???
Ha! We are both awake at the same time! It's 11.25 am here in Suffolk, UK. Happy Easter! Bob
+Robert Hawtin Happy Easter mate, be sure to go easy on the eggs!
Amazing ! For the risk of it bending and breaking, maybe you can make 2 of these, at half the length, one for the start and the other for the square finish
Excellent video Chris.
+Greg's Garage Cheers Greg :)
Never knew such a tool existed. That is really cool! I'm glad I ran across this channel!
Thanks for another very helpful video. This is a very worthwhile project considering the price of broaches. I guess I need to get some square tool steel and get to work.
+Jeff Iscool Cheers Jeff, thanks for watching
Love your video editing, awesome lightning and the macro shoots are so neat!
Nice job!!
Ridiculously beautiful
great job really enviable precision and delicacy of your labors and tmb is very good quality recording, congratulations from Argentina
+Camilo Di Chiazza Thanks for watching :)
Great video to relax my tired soul
Excellent detail and top quality video with impressive editing. Thanks for sharing mate.
Thanks for another great video, love your calm easy teaching style.
+Andrew Wilson Great to have you watching Andrew :)
Yes, had to do multiple small size broached holes for Allen key and pushing on a lathe or press gave your sphincter muscles a work out! Much better to pull, this was in Stainless.
I'm glad that you're back at it with some amazing video's Chris!
+𝖘 𝖍 𝖎 𝖗 𝖔 Cheers mate, thanks for being patient :)
I'm disappointed by the lack of a decorative blueing.
+PastyNoob Ha ha! And no polishing either!
Many thanks - I have often wondered how square holes are made!
Nice video man, you're the best machinist I have ever seen, keep up the great work! 👍🏻