Detailed Rotary Broach
ฝัง
- เผยแพร่เมื่อ 2 มิ.ย. 2024
- Detailed version of my #TMC2020 entry where I build a rotary broach.
A rotary broach lets you cut internal (and external) features such as a hex, spline or a square into an existing hole. This is very useful to make custom tools.
I also have a cinematic version of the build here:
• Cinematic Rotary Broac...
All of my links:
linktr.ee/Tom.Make.Here
Here you can find plans, tools for sale, behind the scenes and other ways of supporting me
Some easier broach grinding methods here:
• Easy Rotary Broach Too...
Big thank you to Emma and Steven for hosting and judging the competition entries this year
/ emmawatchrepair
/ rslng52
The special steels used (4140 and 1214) are from Tyne Valley Metals. Check them out for some offcuts.
www.ebay.com.au/str/tynevalle...
/ tynevalleyenterprises
I plan to do more videos soon where I show where certain steels provide benefit. Stay tuned.
Competition playlist here, go and give the other entries some love!
• #tmc2020
Please excuse the noise from the rain in places
0:00 Plan overview
0:34 Making the backplate
1:38 Starting the body
1:55 How to bore to a shoulder
2:51 Cutting grooves in the body
3:21 Drilling the body flange
4:05 Interesting metrology technique
5:20 Adding material back to a bore
6:30 Making the spindle
7:14 Setup to grind hex tools
8:19 Grinding the hex tools
8:48 Assembling the tool
9:19 How a rotary broach works
10:16 Testing the tool
12:15 The money shot - วิทยาศาสตร์และเทคโนโลยี
![โอ้มายก๊อด! ไม่ถึงชั่วโมงหมดเป็นแสน 😅 [cc] แดนแพทตี้ SS2 | EP.42 |](http://i.ytimg.com/vi/OH2ShXfO6tA/mqdefault.jpg)
i don't get why you need it to spin? why not push it in without the chuck spinning?
It's hard to see, but the tool in the tailstock is spinning at an angle. Only one tip of the hexagon is in contact at any time. As the lathe spins it drags the broach bit along until the next tip makes contact instead. That tip then nibbles at a bit of material, before the next tip comes in contact. This Old Tony has some good videos where he explains the process
It is black magic until you get you hear around it ha ha
@@TomMakeHere awesome thanks for the detailed reply. more to it than it looks then haha
Thanks for asking this question!
I have a part that needs a hex in it. I've been thinking about why it needs to spin also.
xD then it would be round hole OR tool broke,
but no one stop you push it in without turning anything. it just need lotsa power
@@dans_Learning_Curve Doing it with the rotary action, with only one edge of the broach being in contact with the work at a time, just requires a lot less push force to plunge the broach into the hole. You certainly could just drive it straight in, and that would work, but it would require using something like a hydraulic press. I suppose you could drive it in with a hammer as well, but that might be a pretty crude way of doing it, with the risk of damaging or breaking the broach.
Brilliant, Tom. Love hearing the explanations and seeing the details.
Cheers Craig
Yep bought the plan can’t wait to get started
Awesome. Let me know if there are issues or any improvements
Beautiful work, thank you very much!
Thank you, glad you liked it
Enjoyed that. Thanks for the details. Will watch it again when I make something similar down the line. Good luck with the TMC 👍😎👀
Cheers. Yeah I think it will be handy with future toolmaking
Great tool and video Good luck I can't wait to watch your other videos
Cheers!
Thanks for watching
Thanks for sharing, both videos are amazing!!!
Cheers! it was fun to make and to film!
Thanks for watching and commenting 😁
Nice thing to make, and very well finished too!
Thank you! I'm going to have a lot of fun with this tool
1:46 - LMAO OMG dude using the rust for machinists blue was a brilliant move... I love it!
Ha I do it all the time it works well :)
Wow, loved your video. Well presented and will be downloading the plans
Keep up the great work i see you on emmas wednesday live from time to time.
Thank you for sharing
Awesome! Thank you for watching
Beautiful work! I like your style.
Thank you very much!
That's a great video. Very ingenious measuring techniques!
Cheers John. I really need to fill in some holes in my measuring equipment lol
TommyGun Machining less is more! Where did you find the cutting disks?
@@CreaseysWorkshop It certainly forces my to be creative lol
I've gotten all of my grinding equipment from RS au.rs-online.com/web/
Nice one. Great vid. Thanks for sharing
Thanks for watching
Thank you for sharing. This is different broaching than I’m used to. I’ve seen broaching bars that cut inside splines in GM Front wheel hubs, I’ve broached key ways. But not this way. Think I might try this in my home shop. Great job
Yes and you can make all of those shapes provided you have the right broach
very nice! Thanks for sharing
Thank you! Cheers!
nicely done!
Thank you! Cheers!
Excellent vlog.
Thank you!
Great video. You do very nice work, both in the content and delivery.
Thank you. Just need to find time to make more videos
One of those tools that I comprehend without fully understanding 😁 Nice job Tom and welcome to my subscription list.
They are borderline black magic lol
Thanks for the sub
Love to have one of those rotary broach tool great video
I can see it being useful
Thanks for watching
Great job!
Thank you! Cheers!
Fantastic tool build and video, that's s tool I've been wanting to make for some time.
Me too. Go for it!
Very well done. This really makes me want to do some rotary broaching.
Go for it! It's a fast and easy process
I must admit I look for excuses to use it ha ha
Great tool , nice job . Cheers
Cheers. Is there a beautiful 'Project XI' on the way, or is the shed build using up too much of your time?
@@TomMakeHere I have to sit the TMC out this year as the shed takes priority & i am only just coming to an end with the R8 tooling series . Time is something there is a shortage off !
Very good work.
Thank you!
Great great job very well explained thanks
Glad it was helpful!
very good video..thanks for your time
Thank you for watching
Gday Tommy, brilliant build, interesting measuring problem solving, definitely a great tool to have, great video mate.
Cheers Matty.
I think it could be a cool option with the surface plate, technically I can now mic a 300 mm internal bore (not that I expect that type of work)
It's just extremely touchy to set the gague
Nice! Another tool on the "I want to build it someday" list, thanks for sharing!
Cheers. It's been on my list for ages lol
Very brilliant
Thank you
Very nice. Your tequenics used is very superb with available tools. This is called by the name of Efficient Machinist. Thank you. 💯🤝
Thank you. I do like having minimal tools as it forces me to be creative and come up with new methods.
and I'm a cheapskate who doesn't like sending money 😁
Nice work Tom. Good video as always. Regards Kevin
Cheers Kevin. Also congrats on 1k subs
Good stuff. Going threw some of your videos. Glad I subscribed. Nice work
Awesome, thank you!
Very interesting.
Thank you
nice job man!! i will do it....
tnx for video
No problem 👍
Good recovery from the mistake. Turned out great.
Cheers!
Yeah I was worried I'd have to start again for a little bit
Hello from Norway. Thumbs up. Very nice. Carl
Cheers! Thanks for watching
Brilliant work, my friend. I think you did a great job. Best regards from Spain, and good luck in time for the COVID-19
Thank you very much! Sorry, I only just saw this comment!
Awesome!
Thanks!
Great Job congratulation
Thank you
very nice!!
Cheers!
Thanks for watching
Beautiful work as always. We posted this video on our homemade tools forum :)
Awesome! Thank you!
@@TomMakeHere You're very welcome. You can contact me at jon at our website url, and I'll give you a code to join our forum for free, and you can post your videos whenever you want. Looks like you're one of us :)
Dunno man, liked the cinematic version but also like this one ... can t choose between em. Nice videos, keep them coming 👍🏼 good day
Cheers! Hopefully that means they were both good
TommyGun Machining F*ckin’ A mate 👏🏼👏🏼👍🏼
I am impressed by your collection of rusty old crap.
umm thanks? 😂
Mitutuyo brand..very nice
Tommy!!!! Hello again here is your #1 fan
Definitively you are the “Beast”
Cheers!
I wrote my autograph, but the sharpie appears to just be stuck on the screen at my end. Maybe it will come through to you soon
Nailed it!
Cheers!
I'm very happy with the result
what i use to cup out tip is an old carbide drill i ground with shallow angle and for side clearance on broach i shim up end of spindex with a .015 shim works out to a degree and a half
Ah nice that is a really good method
How long do the drills work on HSS out of interest?
The bearing is correct. Back check it with some gauge blocks and that same mic. Earlier in the project when chucking you need to check for whip.
I tried building one a few years ago but it broke my tool bit on the first try, and haven't tried it since.. It should work though unless something is very off. I got a tool grinder since then so maybe I should try it again.. Thanks for reminding me.
It sounds like the tool alignment was off centre maybe?
Sounds like you have a plan
Thanks for watching
Hi Tommy
I liked your video very much so I subscribed, from Coventry in U.K 🇬🇧.
Awesome, thank you!
Grazie mille, lo costruirò presto.
Grazie! È un ottimo strumento
I recognize that laugh near the end of the video. Nice build
You mean the 'it actually worked and I'm happy with it' laugh?
Gotta love those
@@TomMakeHere exactly. I have had a few of those on my videos as well. Great project. I am currently working on a unique tap wrench design for the TMC, but I can already see you got me beat hands down :-)
@@craigtate5930 There are 3 categories, and the audience exposure is perhaps one of the the biggest benefits that comes out of the competition
@@TomMakeHere oh yes, a few extra views is definitely a nice addition
Thank you for your entry. Are you going to make the drawing available? How do you retain the cutter in the housing?
Plans are available in the link below. There is a set screw in the front flange. It didn't really get shown in the video. In the revised plans I've also added a flat on the broaches
Very good video and I would love to buy one.
I will announce something around the new year
Stay tuned 😁
Very cool Tom, nice big chunky rotary broach, good job mate! and good thinking on the measuring for when you didnt have a bigger mic! :D
Cheers! I like to experiment with new techniques like that.
It is insanely touchy to measure this way, but it worked in the end
@@TomMakeHere got it done and thats what counts man :) plus its another little trick in your pocket in case you need it down the line
@@TomMakeHere One of your future projects. How to make a zero to six inch micrometer from a G clamp.😅
@@howardosborne8647 Sounds very precise 🤔😂
Thank you
You're welcome 😁
Hi,
I just bought your plans for the Rotary Broach. What bearings are required? I love your videos, I learn so much from them. Cheers
Bearings are specified on the second and 3rd page. The plans should have been sent to your email automatically. If not, let me know and I will send direct
Well done ! I'm jealous of the surface grinder , but I have a 1 - 2" Mic !! ;)
Yeah for my size of workshop that machine is a beast
I need to fill major holes in my tools, I've focused more on bigger stuff
@@TomMakeHere a set of slip gauges ,a vernier height gauge ,a granite surface plate but no 25-50 mm Mike ! That made me smile ☺️
5 mm backlash at compound is hillarious! :D
Shh I know. On the plus side it is bad enough that there is no way I could forget about it lol
I need to adress it before if fully strips lol
gday tommy just came across your video on the rotary broach that looks fantastic i love your approach
to the way you tackle things just like a ausie we don't have a lot of finance's but a hell of lot of enthusiasm
looking forward to more videos when you get more proficient with the surface grider will you be do'ing
some precision ground flat stones i did hit the sub and bell cheers
Cheers mate
Yeah I have a lot of projects planned that will make use of the grinder
Thank you my friend, I know how to make this tool
Thanks for watching!
*excellent video thank you very much I subscribe*
Awesome, thank you!
Love the videos, keep them coming. What is the lathe that youre running? looks a bit like mine. (leBlonde Regal)
Cheers it's a 9C Hercus. Basically the Australian South Bend clone
Awesome work I just purchased your broach and chamfer tool plans. Id be interested in some of your trigonometry im not sure if anyone else would but I would haha. Nice problem solving on the surface plate
cheers! I might include a bit more in some videos. Trying to find a balance between detail and video pacing
i work at polygon solutions,well done young man.
Cheers!
Savagestyle,I think it time you published some downloadable plans and give up charging a small fortune for rotary broaches.😂
Amazing job, seems like 1040 would have been a better choice given the time and effort?
Absolutely, I used the steel I had on hand
I refer to this as the prototype, I honestly didn't know if it would work!
Thanks for watching
Watch out press fitting bearings too tight, it can tighten up the clearance too much.
Well done explanation and very interesting content. Perhaps you could start the broach with the work stationary, especially if you are trying to line up with a false start.
Thanks, first time viewer!
I learnt that recently the hard way luckily it wasn't too bad in that case.
I can't remember if I mentioned it in the video, I tried to relieve the entry of the bores so the press was only right at the back. It seemed to work for me
Thank you very much
We enjoyed
You need acup of coffee now😃😃😃
Thanks for watching ☕
I would like to but the broach tool but it sounds a bit expensive. I will look at the plans.Thanks for the vid nice job.
No worries, that's why I have it as an option
I'd be interested in parting with some legal tender if i got a cool rotary broach.
Cool I'll see if I get a few more people interested before I commit to a batch
@skyydiver72 Stay tuned. I'm on track to announce something around the new year
love the work. About cutting fluids. You seem not to use any. Is that for the video?
Thank you
I run carbide dry and HSS tooling I typically brush oil on with every pass
Time to shim the bushing on that compound.
Yeah it was really crapped out 😅
Hi .
Nice video.
We have the same style. Editing a video took a lot of time and work.
Thumb up.
Cheers mate!
Thanks for watching
Again, very well produced video. Seems like you shot on a great camera using a professional videographer.
Btw, great concentration face 😂😂
Ha ha nope, just a one man band. It's all about the lighting
🧐 Maximum focus ha ha
You have a lathe, a surface grinder, a mill and a bandsaw, but only 1 micrometer?
Shh! My focus has been on collecting bigger tools (good but cheap where I can) to expand my capability.
Now to fill in the holes!
I don’t have a mill…any tips for getting the 1 degree offset without a mill?
Yes, have a look at the channel 'Craig's Workshop'
I just purchased a plans download from you. If it all goes wrong I suppose I can re-purpose the fluted body as a novel pepper pot or some such.😨
I left the flutes off the drawing but feel free, the world needs more fancy pepper pots! You can watch Matty's Workshop on youtube, he's documenting the full build
@@TomMakeHere I've already watched Matty's wobble broach build and it will be helpful for my own effort. Your technical plan drawings are very nicely done. I look forward to printing them out on some heavyweight paper later on. Might even push the boat out and laminate them.👍
Does broach can come out while taking back after broaching.
There is a set screw holding the broach tool in place. It's not very apparent in the video
Can I use commercial broaching bits with it?
I've sized my design to work with 10 mm HSS. I think commercial bits are 0.5" diameter
Nicely done. I like the inclusion of the boo boos (undersized tooling, lack of chamfer, and such)...nice to know I'm not the only person who makes boo boos.
Ha ha yep, none of us are perfect!
Thanks for watching
You have slip gauges but not a 25-50 mike? ?? Why the sleeve instead if machining directly to suit the bearing??
I got gauge blocks cheap from an auction. So far I've not needed to work in that size so much
Plus i wanted to experiment with different methods
Muito bom esse vídeo, tudo o que eu preciso pra fazer sextavado nas minhas peças.Parabens!!
C
great video made a rotary broaching tool years ago used it no more then 5 times one of those tools you have to have but never really need bolts so cheap now not worth making
Cheers. I plan on using it for custom toolmaking fasteners. There have been several times I've had to use the angle grinder to put in a crappy screw driver slot.
I also see the benefit of a square broach for making a seat for a HSS tool, and plan on experimenting with broaching keyways too
What software do you use to draw the plans?
I used solidworks but fusion360 is a good alternative
Did you ever do a production run of these?
I did a couple. I'm taking a break from making them until I upgrade my jigs. Then I'll make more
what material for the cutter bit?
It is high speed steel
Out of curiosity, how much (US Dollars) would/do you charge for one?
Based on current conversion rate $171 USD for the body, $209 USD with a pack of broaches.
I'm looking at ways to make things more efficient as I would like to offer it cheaper if I can
Hello friend: I'm from Brazil: please, could you pass the measurements of the bearings, thank you in advance. Congratulations on your project.
I ordered a set of plans but nothing has arrived. Is it a snail mail delivery?
Hi Mark, the plans should be sent automatically by etsy to your email. Maybe check your junk folder?
I will double check tonight when I'm at a computer
I've emailed the pdf plans just to be sure
Let me know if you don't receive it
Молодец!
Спасибо
Why did the bearings not get any grease or oil?
They did receive some spindle oil, I did a dry assembly for the video so I wasn't getting oil on equipment while operating the camera
Good pick up
TommyGun Machining good to know. I’m just really paranoid because I forgot to add grease to a bearing once and experienced a catastrophic failure.
Sirve para torno y fresa ?
Sí, funcionará en ambas máquinas.
@@TomMakeHere genial, muchas gracias
Bravo Turkey İzmir den selâm
izlediğiniz için teşekkürler
I’m interested in buying the broach.
Awesome, I have plans, tool bits or the whole tool available here: www.etsy.com/au/shop/TommyGMachining I am about to start a batch soon, so good timing!
Qual a marca de sua fresadora? Obrigado.
É um Hercus Mk2 australiano. Obrigado por assistir!
@@TomMakeHere Obrigado, parece muito boa!
Bom dia, irei comprar o projeto: "ROTARY BROACH"
how much for the tool?
seems like it doesn't need to spin at all.... its just spinning with the part as you shove it in there like a normal broach minus the spinning.
The only benefit to using the lathe is getting it dead center.
Definitely needs to spin, I wouldn't be able to push it through when stationary
Because it is off axis, only one point is contacting at a time and this massively reduces the pressure required. Then as it rotates another point makes contact
but how the tool fixed inside...?
There is a set screw, you never really see it in the video though
Ola boa tarde
O sr pode me ceder onde vende este
Manual detailed rotary braoch
Lourival ribriro
Parque sao vicente
Maua sp
BR
Vida longa e prospera
www.etsy.com/au/shop/TomMakeHere
Tenho planos para minha loja. No momento não tenho nenhum broche para venda, desculpe. Espero fazer mais no final do ano