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Broaching vs. Forging a Square Recess

Broaching vs. Forging a Square Recess

Broaching vs. Forging a Square Recess

Hi all,

I have a drill driver shaft (0.33" diameter) that needs to have a square recess (3/4" depth) machined into one end. I'm just wondering what the typical/best process would be for this operation. Would it be better to forge or broach this recess? The length of one side of the square for the recess is 0.150". Ideally I'm looking at a tolerance of +/-0.001". Also, any idea how much it might cost to have a shop make a few prototypes of this before production? Suggestions of machine shops in the US would be helpful. Also places that I can have this forged.


RE: Broaching vs. Forging a Square Recess

The allowable corner radius will have a big effect on the processes available.
That's also a pretty deep hole.

Mike Halloran
Pembroke Pines, FL, USA

RE: Broaching vs. Forging a Square Recess

to my knowledge forging is out.
broaching maybe send out for quotes

if it can be built it can be calculated.
if it can be calculated it can be built.

RE: Broaching vs. Forging a Square Recess

Typical l:d ratio for forging (cold or hot) is limited to ~ 3:1. It is common to forge an initial recess and then drill/rotary broach a deeper recess with improved accuracy/precision. There are other options depending on quantity needed. Is this a high quantity application that can justify dedicated tooling?

RE: Broaching vs. Forging a Square Recess

With the tolerance you are requesting I believe drilling a hole and then using EDM to make the square would would be your best approach for your samples. Making production parts will also be difficult .150 square .750 deep.


RE: Broaching vs. Forging a Square Recess

What about a hex recess with a flat to flat dimension of .189"? Will achieving a recess depth of .75" be difficult for most machine shops through traditional push broaching? Me may have to relax the tolerance to get to this depth

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