Can someone please explain to me the broaching process for putting a hexagonal recess into a screw driver shaft. I've been asked to figure out why our shafts keep breaking, and I want to understand more about the broaching process to see what parameters can be optimized. It appears that the surfaces of the hex recess are rounded, is this normal? Ideally I would want these faces to be flat in order to impart an equal amount of stress on each face, but if it's an artifact of broaching then maybe there's no way around it. I'm assuming there's a pre-drilling step which makes it so these surfaces aren't completely flat, but is there a way to broach these surfaces and keep that face flat? (without any severe increase in cost). The hex flat to flat dimension is 0.192". Also, what type of tolerances can be kept with this process?
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