Broach Rotary Hassay NT

Hassay Savage Company
Precision • Performance • Profitability

distributed by :
Newman Tools Inc.

Tel 1-800-465-1384 Fax 1-800-605-2442
Tel 613-836-6776 Fax 613-836-9070
www.newmantools.com
Oct 2010
Our History
Founded in 1969, Hassay Savage Company begins its
fourth decade as a family-owned manufacturer of pre-
If the broaching process proves to be the more cost-effec-
tive approach for your manufacturing process, a Hassay
cision broaches. In our first forty years, we have estab- Savage precision broach is the solution. Our standard or
lished our reputation at the forefront of broaching sys- special broaches are ground by our technically advanced
tems as a producer of quality standard broaches and manufacturing systems to meet the most exacting specifica-
bushings while increasingly proving our capabilities in tions. A Hassay Savage high-speed steel broach has longer
the area of customized broaching. We intend to main- life, gives cleaner cuts, and requires less frequent sharpening
tain both the standard and special broaching needs of and replacement.
our growing customer base.
Talk to one of our engineers today about
your broaching needs. At Hassay
Since 2005, the resurgent tool-
Savage we listen to your concerns; we
making industry faces an excit-
will work with you to meet your prod-
ing challenge to provide cost-
uct goals while increasing your profit
effective solutions for our com-
margin. Your business is our business.
plex industrial society. Hassay
Savage’s achievements rest on
Our catalogue provides you with the
the shoulders of the company’s
information you need either as you con-
skilled tool and die makers. We
sider for the first time the broaching
are committed to supporting our
alternative to reaming, milling or shap-
fine craftsmen with the necessary
ing; or as you consider turning to
state-of-the-art resources: in
Hassay Savage for tooling or retooling
design (AUTO-CAD), in comput-
your broaches.
erized and process manufactur-
ing (CNC and CAM), and through process control Hassay Savage presents a comprehensive line of high-
and process analysis (SPC). In doing so, we stand speed steel broaching tools capable of critically accurate
ready to address your broaching applications, ques- cuts in many configurations while producing extraordi-
tions and problems—and to make solutions for you. nary smooth surface finishes.
We can show you how broaching can be a superior, cost-

Hassay Savage Company is in the business of making
effective alternative to other machining processes custom-
quality standard and special broaches because we
arily employed to mass-produce identical parts.
believe broaching can provide our customers with
greater profit. Our full line of services include: Hassay Savage delivers topnotch, well-engineered, and
• cost analysis of broaching versus other machining profitable broaching tools, off-the-shelf or custom-designed.
processes; Our turnaround times are among the best in the industry.
• complete design assistance;
• warranty-backed product;
• quick delivery.
www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

Contents
Types of Broaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
One Pass Keyway Broaches Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
American Standard Keyway Broach sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Metric Keyway Broach sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Combination Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Heavy Duty Keyway Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
American Standard Keyway Broaches, Bushings and Shims . . . . . . . . . . . . 9
Metric Keyway Broaches, Bushings and Shims . . . . . . . . . . . . . . . . . . . . . . . . 10
Standard Inch, Full, Metric Square Broaches . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rotary Broaches, Holders & Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Internal Hex Rotary/Punch Broaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjustable Rotary Broach Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Use Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rotary Broaching Set-Up Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjustable Rotary Broaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
How to Set UpAdjustable Rotary Broach Holder for CNC Machining . . . . 18
Rotary and Index Broaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Non-Adjustable Rotary Broach Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CNC-Indexable Single Point Keyway Broaches . . . . . . . . . . . . . . . . . . . . . . . . 21
Standard Inch Square Push Broach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hexagonal Push Broach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Davis Style Keyseating Broaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
500 & 600 Series Pull Type Broaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Broaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Broach Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Broach Grinding Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cost Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rebuilding and Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Tool Materials Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Using and Troubleshooting Broaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Broach Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Special Broaches at Hassay Savage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-35
Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Broaching Machinery Available Through Hassay Savage . . . . . . . . . . . . . . . 36
Note to our Distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Custom Broaching Request Form Inside Back Cover . . . . . . . . . . . . . . . . . . . 37
Warranty
Hassay Savage Tools are warranted free from defects in mate- otherwise modified, or tools which after examination prove to
rial and workmanship in all cases of normal use. If under have been abused, or are without flaws in material or workman-
conditions of normal use a tool fails, it shall be repaired or ship. Government regulations require use of safety glasses and
replaced, at our option, when shipped prepaid to our factory other appropriate safety equipment in the vicinity of use.
in Turners Falls, Massachusetts 01376.
Hassay Savage Company, Inc., authorizes no other warranty
This warranty is made in lieu of all other warranties expressed by any other person or agent, nor recognizes as binding any
or implied. This warranty does not cover tools which have warranty made by such person or agent on our company’s
been stamped for identification, experimented upon, or behalf. We assume no further liability, except as stated herein.
Credits: Jane Gotlieb for cibachrome hand-p ainting of photographs on front and
back covers; Hyam Siegal, Edward Judice for photography except where noted.

Types of Broaches
Broaching is a precision metal-cutting process Broaching processes and tools are classified first
which incorporates a series of rough, semi-fin- as surface or internal; then as standard or special.
ished, and finished teeth designed to remove suc- Each broaching tool is designed to fit the starting
cessive portions of stock as the tool moves through print; its length and number of teeth are set by the
or across a workpiece in a one-pass linear opera- kind of stock (e.g., machined, cast, or forged) and
tion. Each tooth is calibrated to remove only a amount of metal to be removed.
small amount of stock appropriate to the type of
material broached, which permits continuous
clean chip removal.
Surface Broaches
Surface broaching is the most commonly used in Surface broach (used
as set of 2) to broach
place of milling or shaping operations on surfaces two flats on CAM-actu-
of material parts or components. Surfaces may ated valve.
be flat, concave, convex, serrated, or cam-shaped.
The tool is a simple flat bar with multiple rows
of cutting teeth, usually attached by bolting Special rec-
or clamping onto a broach holder. Surface tangular push
broach for
broaches can also be manufactured as insert highly sensi-
sections and configured in a broach holder. tive fluid
Thereby lowering the costs of initial metering
device
manufacturing and replacement.
Surface broaching is especially effective

when compared to other machining methods
because it produces highly finished surfaces of
complex shapes with exacting dimensions and
tolerances at a rate many times faster than the
milling or machining processes.
Standard Broaches
The strength of our business at Hassay Savage
has been built upon standard broaches available
from stock and shipped on the same day the Standard
push key-
order is placed (see pages 5 through 25). We way broach
are one of a very few broach manufacturers who and guide
sell standard tools from stock, which means we can system
bushing; for
satisfy our customer’s needs immediately. 1/4” keyway
in idler
mechanism.
Our sophisticated system of market
distribution (400 industrial distributors and
four factory warehouse locations) permits
product to be in the customer’s plant when
most needed.
2
Internal
Broaches
Starting with a round drilled hole,
internal broaching can mass produce
practically any internal hole configura-
tion from the simplest application,
reaming-to the most complicated, the
rifling of gun barrels. Almost all inter-
10-tooth spline
nal broaching is done by pull broaches pull-type involute
because they significantly remove form; internal
gearing.
more stock than push broaches, even Standard inch
where the workpiece has a thin or square for
broaching
irregular wall. Also, a pulled internal mechanical
broach can handle longer lengths of housing.
cut.
Internal broaching tools include the Double D pull

broach for
following: round pull, round push, table saw;
rotor cut style, straight spline and ser- adjustment
ration, involute spline and serration, screw.
combination round and spline. They
are faster and more economical than
any other machining process: from
round, and all derivative shapes of
round, to internal gear spline, helical
splines, and other irregular shapes.
Internal broaching solves scores of

manufacturing applications that sim-
ply cannot be done any other way. For
instance, there is no other way to make
a precise square hole.
Special
Broaches
Surface applications include flats, notches, serra- The engineering and
tions, slots, intricate contours, turbine forms, key design department at
lock slots, connecting rods, external gearing.
our company offers a complete line of services for
Internal applications include tooling fixtures, gear production of special broaches. As shown on pages
and pulley keyways, keyways, rifling, hole configura- 34 and 35, we are expanding considerably in this
tions in all geometric shapes.
sector of the broaching market.
Our engineers can integrate the design and manu-

facturing process of your custom broach.

Keyway Broaches - American Standard
Hassay Savage HSS Keyway broaches and bushings are clear-
keyway broaches ly marked as to size, and any I Broach
are available as can be used with any I Bushing, and II
standard items in Broach with II Bushing, etc.
sizes 1/16” to 1.”
Rake and relief

angles are precisely
made for efficient
broaching of mild Hassay Savage VI ing additional or
steel. bushings are avail- replacement shims,
able on special order specify EDP
in dia. sizes 3 1/4” Number.
Pressures listed in chart on facing to 4 1/2.” Required
page are for maximum length of shims are supplied Shims correspond to
cut. If these lengths must be for each keyway broach size, not to
exceeded, a special Hassay Savage broach. When order- bushing size.
keyway broach should be ordered
for specific length of cut. In the
event of thin pieces, pieces may be
broached by stacking and nesting.
Length
For special widths and depths, cus-

EDP
tom keyway broaches are also Collared
available within a 1 - 2 week peri-
od. This is an excellent delivery for
the buyer looking for a special Length
application in production or Length
prototype.
Plain Width
Bushing Thickness
Bore
Standard broaches may be ordered through your Size
nearest Hassay Savage industrial distributor for
off- the-shelf-delivery. When ordering from our
standard stock, specify the EDP number with type
and size as listed in the appropriate table
All of Hassay Savage tools are available with tita-

nium nitride coating as a standard product.
4
Keyway Broach Sets- American Standard
Keyway Range; 1/16 - 3/8”
Precision Set 1 Collared EDP No. 15315
3 Broaches and 5 Collared Bushings
15 Keyway Combinations Wt. 5 lbs.
Keyway Broach
Sizes Style Bushing Diameters (Hole Sizes)
1/16 I
3/32 I 1/4, 5/16, 3/8, 7/16, 1/2
1/8 I
Standard Set C-1 Collared EDP No. 15318

Keyway Broach
1/8 II
1/2, 5/8, 3/4, 7/8
3/16 II
1/4 III
1, 1-1/8, 1-1/4, 1-3/8, 1-1/2
3/8 III
Standard Set C-1A Collared EDP No. 15319

Keyway Range; 1/16 - 3/8”
in Dura Case
Hassay Savage HSS broach sets come in Keyway Broach
durable plastic boxes and include broaches, Sizes Style Bushing Diameters (Hole Sizes)
bushings, shims and instructions. 1/8 II
9/16, 11/16, 13/16
3/16 II
1/4 III
These specification charts describe the dimen- 15/16, 1-1/16, 1-3/16, 1-5/16, 1-7/16, 1-9/16
3/8 III
sional cuts, configurations, tolerances, cut
lengths, and machine tonnage for each standard
broach we manufacture.
Selecting a standard broach from Hassay Savage
is a simple process. Choose a tool, or set of tools Keyway Broach
that will produce the cut your finished part
requires. Specify the EDP, size, and brief descrip- 1/8 II 9/16, 11/16, 13/16
tion when ordering to ensure proper delivery. 3/16 III
15/16, 1-1/16, 1-3/16, 1-5/16, 1-7/16, 1-9/16
1/4 III
All standard products are maintained in finish
good inventory. Often we can ship your order the Standard Set C-2A Collared EDP No. 15321
same day it is placed. Additional special widths 3 Broaches and 9 Collared Bushings
and lengths are also available from semi-finished 14 Keyway Combinations Wt. 10 lbs.
stock ground to your specifications with quick Keyway Broach
delivery. Sizes Style Bushing Diameters (Hole Sizes)
1/8 II 1/2, 5/8, 3/4, 7/8
All tools listed are also available with titanium 3/16 III
1, 1-1/8, 1-1/4, 1-3/8, 1-1/2
nitride coating as a standard product. Contact our 1/4 III
customer service for details

Keyway Broach Sets- Metric
Keyway Range; 2mm - 8mm Precision Set #10 Collared EDP No. 15410
Keyway Broach Metric Bushing
Sizes Style Diameters (Hole Sizes mm)
2mm I
6, 7, 8, 9, 10
3mm I
Metric Set #40 Collared EDP No. 15440
2mm I
8, 10
3mm I
4mm II
12, 14, 16, 18
5mm II
6mm III 18, 19, 20, 22, 24, 25,
8mm III 26, 28, 30, 32, 34, 36
Metric Set #18 Collared EDP No. 15418
4mm II
12, 14, 16, 18
5mm II
6mm III
20, 22, 24, 26, 28
8mm III
Metric Set #24 Hardwood EDP No. 15224
3 Broaches and 8 Plain Bushings
Shims 24 Keyway Combinations Wt. 36 lbs.
10mm IV
12mm IV 34, 36, 38, 40, 42, 44, 46, 48
14mm IV
Collared
Bushing Metric Set #12 Hardwood EDP No. 15212
16mm IV 54, 56, 58, 60, 62, 64
18mm IV
Metric Set #30 Hardwood EDP No. 15230

Plain Bushing Sizes Style Diameters (Hole Sizes mm)
14mm IV 44, 46, 48, 50
16mm V 52, 54, 55, 56, 58, 60,
18mm V 62, 64, 65, 66, 68, 70

Combination Sets- in Dura Case Boxes
American Standard Sets
Keyway Broach
1/8 II
1/2, 9/16, 5/8, 11/16, 3/4, 13/16, 7/8
3/16 II
1/4 III 15/16, 1, 1-1/16, 1-1/8, 1-3/16, 1-1/4,
3/8 III 1-5/16, 1-3/8, 1-7/16, 1-1/2, 1-9/16
Dura Case Broach Kits

Standard Set C-10A Collared EDP No. 15330
Meeting the needs of today’s industry, Hassay 3 Broaches and 18 Collared Bushings
Savage broaches find use wherever precision 30 Keyway Combinations Wt. 16 lbs.
broaching operations add to the quality and eco- Keyway Broach
nomical manufacture of identical parts. Sizes Style Bushing Diameters (Hole Sizes)
1/8 II 1/2, 9/16, 5/8, 11/16, 3/4, 13/16, 7/8
All broaches are CNC-qualified. 3/16 III 15/16, 1, 1-1/16, 1-1/8, 1-3/16, 1-1/4,
1/4 III 1-5/16, 1-3/8, 1-7/16, 1-1/2, 1-9/16
DIN Standard For Keyways

Keyway
Size
Bushing
Diameter mm
DIN Standard Metric Sets
2mm 6 - 8mm
3mm 8 - 10mm
4mm 10 - 12mm
5mm 12 - 17mm EDP No. 15440 DIN
6mm 17 - 22mm 6 Broaches and 13 Collared Bushings
8mm 22 - 30mm 26 Keyway Combinations Wt. 12 lbs.
10mm 30 - 38mm
12mm 38 - 44mm Keyway Broach Bushing
14mm 44 - 50mm Sizes Style Diameters (Hole Sizes mm.)
16mm 50 - 58mm 2mm I
18mm 58 - 65mm 8, 10
3mm I
20mm 65 - 75mm 4mm II
22mm 75 - 85mm 12, 14, 15, 16
5mm II
24mm 85 - 95mm 6mm III
25mm 85 - 95mm 18, 20, 22, 24, 25, 28, 30
8mm III
EDP No. 15410 DIN EDP No. 15224 DIN
10 Keyway Combinations Wt. 5 lbs. 3 Broaches and 7 Plain Bushings
Keyway Broach Bushing
Sizes Style Diameters (Hole Sizes mm.) Keyway Broach Bushing
Sizes Style Diameters (Hole Sizes mm.)
2mm I
3mm I 6, 7, 8, 9, 10 10mm IV
12mm IV 32, 35, 38, 40, 42, 45, 50
EDP No. 15418 DIN 14mm IV
18 Keyway Combinations Wt. 10 lbs. EDP No. 15212 DIN
Keyway Broach Bushing 10 Keyway Combinations Wt. 5 lbs.
4mm II Keyway Broach Bushing
5mm II 12, 14, 15, 16 Sizes Style Diameters (Hole Sizes mm.)
6mm III 16mm V
18, 20, 22, 24, 25 18mm V 52, 55, 58, 60, 65
8mm III

Heavy Duty Keyway Sets
Standard Set 3-D Hardwood EDP No. 15024
Keyway Broach
5/16 IV
1-1/2, 1-5/8, 1-3/4, 1-7/8,
3/8 IV
7/16 IV 2, 2-1/8, 2-1/4, 2-1/2
1/2 IV
Standard Set 3-DA Hardwood EDP No. 15124

Keyway Broach
5/16 IV
1-7/16, 1-9/16, 1-11/16, 1-13/16,
3/8 IV
7/16 IV 1-15/16, 2-3/16, 2-7/16, 2-15/16
1/2 IV
Heavy Duty Set 4-E Hardwood EDP No. 15012

Tongue and Grooved Hardwood Cases Sizes Style Diameters (Hole Sizes in.)
5/8 V 2-3/8, 2-1/2, 2-5/8
3/4 V 2-3/4, 2-7/8, 3
Heavy Duty Set 4-F Hardwood EDP No. 15014
Sizes Style Diameters (Hole Sizes in)
5/8 V 2-5/16, 2-7/16, 2-9/16
3/4 V 2-11/16, 2-13/16, 2-15/16
Heavy Duty Set 5 Hardwood EDP No. 15026

Sizes Style Diameters (Hole Sizes in.)
2, 2-1/16, 2-1/8, 2-3/16
1/2 IV
2-1/4, 2-5/16, 2-3/8, 2-7/16
5/8 V 2-1/2, 2-9/16, 2-5/8, 2-11/16
3/4 V 2-3/4, 2-13/16, 2-7/8, 2-15/16, 3

American Standard Sizes
Keyway Broaches Bushings Shims
Keyway Length Pressure Bushings Shims
Width Dimensions No.of of Cut Required for EDP Length EDP
Broach EDP No. Tolerance (in.) Shims Min. Max. Max. I/c (lbs.) Dia. length Collared Size Thick. x width No.
1/16-I 10104 .0625 - .0635 1/8 x 5-1/4 0 13/64 1-1/8 270 1/4 1-1/8 20116 1/8-I .031 1-3/8 x1/8 30108
I 3/32-I 10106 .0932 - .0947 1/8 x 5-1/4 0 13/64 1-1/8 810 5/16 1-1/8 20120
1/8-I 10108 .1250 - .1262 1/8 x 5-1/4 1 13/64 1-1/8 720 3/8 1-1/8 20124
7/16 1-1/8 20128
1/2 1-1/8 20132
3/32-II 10206 .0937 - .0947 3/16 x 7 0 19/64 1-11/16 990 1/2 1-11/16 20232 1/8-II .031 1-7/8 x 3/16 30208
II 1/8-II 10208 .1252 - .1262 3/16 x 7 1 19/64 1-11/16 780 9/16 1-11/16 20236 5/32-II .042 1-7/8 x 3/16 30210
5/32-II 10210 .1564 - .1574 3/16 x 7 1 19/64 1-11/16 1,560 5/8 1-11/16 20240 3/16-II .050 1-7/8 x 3/16 30212
3/16-II 10212 .1877 - .1887 3/16 x 7 1 19/64 1-11/16 2,100 11/16 1-11/16 20244
3/4 1-11/16 20248
13/16 1-11/16 20252
7/8 1-11/16 20256
3/16-III 10312 .1877 - .1887 3/8 x 11-7/8 1 13/32 2-1/2 1,440 3/4 2-1/2 20348 3/16-III .050 2-7/8 x 3/8 30312
III 1/4-III 10316 .2502 - .2512 3/8 x 11-7/8 1 13/32 2-1/2 2,580 13/16 2-1/2 20352 1/4-III .062 2-7/8 x 3/8 30316
5/16-III 10320 .3127 - .3137 3/8 x 11-7/8 1 13/32 2-1/2 4,200 7/8 2-1/2 20356 5/16-III .078 2-7/8 x 3/8 30320
3/8-III 10324 .3755 - .3765 3/8 x 11-7/8 2 13/32 2-1/2 3,600 15/16 2-1/2 20360 3/8-III .062 2-7/8 x 3/8 30324
1 2-1/2 20364
1-1/16 2-1/2 20368
1-1/8 2-1/2 20372
1-3/16 2-1/2 20376
1-1/4 2-1/2 20380
1-5/16 2-1/2 20384
1-3/8 2-1/2 20388
1-7/16 2-1/2 20392
1-1/2 2 1/2 20396
1-9/16 2 1/2 20400
5/16-IV 10420 .3127 - .3137 9/16 x 13-7/8 1 3/4 6 9,250 1-7/16 4 21492 5/16-IV .078 6-1/4 x 9/16 30420
IV 3/8-IV 10424 .3755- .3765 9/16 x 13-7/8 2 3/4 6 8,000 1-1/2 4 21496 3/8-IV .062 6-1/4 x 9/16 30424
7/16-IV 10428 .4380 - .4390 9/16 x 13-7/8 2 3/4 6 11,750 1-9/16 4 21500 7/16-IV .075 6-1/4 x 9/16 30428
1/2-IV 10432 .5006 - .5016 9/16 x 13-7/8 3 3/4 6 11,000 1-5/8 4 21504 1/2-IV .062 6-1/4 x 9/16 30432
9/16-IV 10436 .5630 - .5640 9/16 x 13-7/8 3 3/4 6 11,100 1-11/16 4 21508 9/16-IV .062 6-1/4 x 9/16 30436
1-3/4 4 21512
1-13/16 5 21516
1-7/8 5 21520
1-15/16 5 21524
2 5 21528
2-1/16 5 21532
2-1/8 5 21536
2-3/16 5 21540
2-1/4 5 21544
2-5/16 5 21548
2-3/8 6 21552
2-7/16 6 21556
2-1/2 6 21560
2-9/16 6 21564
2-5/8 6 21568
2-11/16 6 21572
2-3/4 6 21576
2-13/16 6 21580
2-7/8 6 21584
2-15/16 6 21588
3 6 21592
5/8-V 10540 .6260 - .6270 3/4 x 15-1/4 4 3/4 6 11,500 2-5/16 6 21688 5/8-V .062 6-3/4 x 3/4 30540
V 3/4-V 10548 .7515 - .7525 3/4 x 15-1/4 5 3/4 6 13,500 2-3/8 6 21692 3/4-V .062 6-3/4 x 3/4 30548
2-7/16 6 21696
2-1/2 6 21700
2-9/16 6 21704
2-5/8 6 21708
2-11/16 6 21712
2-3/4 6 21716
2-13/16 6 21720
2-7/8 6 21724
2-15/16 6 21728
3 6 21732
VI 7/8-VI 10656 .8765 - .8775 1 x 19-1/4 6 3/4 6 11,000 special order in dia. 7/8-VI .062 6-3/4 x 1 30656
1-VI 10664 1.0015 - 1.0025 1 x 19-1/4 7 3/4 6 14,000 sizes 3-1/4” - 4-1/2”. 1-VI .062 6-3/4 x 1 30664
1-1/8 10666 1.1260 - 1.1270 1-1/8 x 23 8 3/4 6 15,750 1-1/8 .062 7 x 1-1/8 30740
1-1/4 10668 1.2510 - 1.2520 1-1/4 x 23 9 3/4 6 14,500 1-1/4 .062 7 x 1-1/4 30750
1-3/8 10670 1.3760 - 1.3770 1-3/8 x 23 10 3/4 6 19,250 1 -3/8 .062 7 x 1-1/4 30760
1-1/2 10672 1.5020 - 1.5030 1-1/2 x 23 11 3/4 6 21,000 1 -1/2 .062 7 x 1-1/4 30770
EDP Bushings I,II and III Numbers 20116 - 20400 are collared.
EDP Bushings IV and V Numbers 21492 - 21732 are plain
9
Metric Sizes
Keyway Broaches Bushings Shims
Standard Metric Keyway Broaches: ISO J-9 Tolerance
J-9 Keyway For Standard No. Length Pressure Bushings Shims
EDP Width Millimeter Dimen. of of Cut Required for Dim. EDP Length EDP
Broach No. Tolerance Keys in In. Shims Min. Max. Max. I/c (lbs.) Size In. No. Size Thick. x width No.
2mm-I 11102 .0782 - .0792 2mm x 2mm 1/8 x 5-1/4 0 13/64 1-1/8 510 6mm-I .2362 22106 3mm-I .031 1-3/8 x1/8 31103
I 3mm-I 11103 .1176 - .1186 3mm x 3mm 1/8 x 5-1/4 1 13/64 1-1/8 720 7mm-I .2756 22107
8mm-I .315 22108
9mm-I .3543 22109
10mm-I .3937 22110
4mm-II 11204 .1570 - .1580 4mm x 4mm 1/4 x 7 1 19/64 1-11/16 1,140 11mm-II .4331 22211 4mm-II .038 1-7/8 x 1/4 31205
II 5mm-II 11205 .1963 - .1973 5mm x 5mm 1/4 x 7 1 19/64 1-11/16 2,040 12mm-II .4724 22212 5mm-II .050 1-7/8 x 1/4 31205
13mm-II .5118 22213
14mm-II .5512 22214
15mm-II .5905 22215
16mm-II .6299 22216
17mm-II .6693 22217
18mm-II .7087 22218
19mm-II .7480 22219
5mm-III 11305 .1963 - .1973 5mm x 5mm 3/8 x 11-7/8 1 13/32 2-1/2 1,680 17mm-III .6693 22317 5mm-III .047 2-7/8 x 3/8 31305
III 6mm-III 11306 .2357 - .2367 6mm x 6mm 3/8 x 11-7/8 1 13/32 2-1/2 1,890 18mm-III .7087 22318 6mm-III .062 2-7/8 x 3/8 31306
22mm-III .8661 22322
24mm-III .9449 22324
25mm-III .9842 22325
26mm-III 1.0236 22326
27mm-III 1.063 22327
28mm-III 1.1024 22328
30mm-III 1.1811 22330
32mm-III 1.2598 22332
34mm-III 1.3386 22334
35mm-III 1.3779 22335
36mm-III 1.4173 22336
10mm-IV 11410 .3932 - .3942 10mm x 8mm 9/16 x 13-7/8 2 3/4 6 8,100 32mm-IV 1.2598 22432 10mm-IV .056 6-1/4 x 9/16 31410
IV 12mm-IV 11412 .4720 - .4730 12mm x 8mm 9/16 x 13-7/8 2 3/4 6 10,550 34mm-IV 1.3386 22434 12mm-IV .056 6-1/4 x 9/16 31412
14mm-IV 11414 .5509 - .5519 14mm x 9mm 9/16 x 13-7/8 2 3/4 6 11,090 35mm-IV 1.3779 22435 14mm-IV .062 6-1/4 x 9/16 31414
36mm-IV 1.4173 22436
38mm-IV 1.4961 22438
40mm-IV 1.5748 22440
42mm-IV 1.6535 22442
44mm-IV 1.7323 22444
45mm-IV 1.7716 22445
46mm-IV 1.811 22446
48mm-IV 1.8898 22448
50mm-IV 1.9685 22450
52mm-IV 2.0472 22452
54mm-IV 2.126 22454
55mm-IV 2.1653 22455
56mm-IV 2.2047 22456
16mm-V 11516 .6296 - .6306 16mm x 10mm 3/4 x 15-1/4 3 3/4 6 11,375 52mm-V 2.0472 22552 16mm-V .062 6-3/4 x 3/4 31516
V 18mm-V 11518 .7083 - .7093 18mm x 11mm 3/4 x 15-1/4 3 3/4 6 12,000 54mm-V 2.126 22554 18mm-V .062 6-3/4 x 3/4 31518
55mm-V 2.1653 22555
56mm-V 2.2047 22556
58mm-V 2.2835 22558
60mm-V 2.3622 22560
62mm-V 2.4409 22562
64mm-V 2.5197 22564
65mm-V 2.559 22565
66mm-V 2.5984 22566
68mm-V 2.6772 22568
70mm-V 2.7559 22570
72mm-V 2.8346 22572
VI 20mm-VI 11620 .7873 - .7883 20mm x 12mm 1 x 19-1/4 3 3/4 6 11,000 20mm-VI .062 6-3/4 x 1 31620
22mm-VI 11622 .8659 - .8669 22mm x 14mm 1 x 19-1/4 4 3/4 6 11,200 22mm-VI .062 6-3/4 x 1 31622
24mm-VI 11624 .9448 - .9458 24mm x 14mm 1 x 19-1/4 4 3/4 6 13,075 special order in dia. 24mm-VI .062 6-3/4 x 1 31624
25mm-VI 11625 .9848 - .9858 25mm x 14mm 1 x 19-1/4 4 3/4 6 13,275 sizes 85mm - 150mm. 25mm-VI .062 6-3/4 x 1 31625
28mm 11628 1.1030 - 1.1040 28mm x 14mm 1-1/8 x 23 5 3/4 6 14,700 28mm .062 7x1 31628
30mm 11630 1.1817 - 1.1827 30mm x 14mm 1-1/4 x 23 5 3/4 6 15,700 30mm .062 7x1 31630
32mm 11632 1.2605 - 1.2615 32mm x 14mm 1-1/4 x 23 5 3/4 6 16,790 32mm .062 7 x 1-1/4 31632
10 36mm 11636 1.4180 - 1.4190 36mm x 14mm 1-7/16 x 23 5 3/4 6 18,590 36mm .062 7 x 1-1/4 31636

Keyway Broaches - Metric
Optional Metric Keyway Broaches: ISO P9 Tolerance
For Standard No. Length Pressure NOTE:
EDP P9 Millimeter Dimensions of of Cut Required for
Standard metric toler-
Broach No. Tolerance Keys in In. Shims Min. Max. Max. I/c (lbs.)
ances are to ISO J9 and
2mm-I 11102P9 .0785 - .0775 2mm x 2mm 1/8 x 5-1/4 0 13/64 1-1/8 510 JS9. Preferred metric
I 3mm-I 11103P9 .1179 - .1169 3mm x 3mm 1/8 x 5-1/4 1 13/64 1-1/8 720
limits and fits --ANSI
4mm-II 11204P9 .1570 - .1558 4mm x 4mm 1/4 x 7 1 19/64 1-11/16 1,140
II B4.2-1978.
5mm-II 11205P9 .1964 - .1952 5mm x 5mm 1/4 x 7 1 19/64 1-11/16 2,040
5mm-III 11305P9 .1964 - .1952 5mm x 5mm 3/8 x 11-7/8 1 13/32 2-1/2 1,680 Optional metric toler-
III 6mm-III 11306P9 .2357 - .2345 6mm x 6mm 3/8 x 11-7/8 1 13/32 2-1/2 1,890 ances are available to
8mm-III 11308P9 .3144 - .3130 8mm x 7mm 3/8 x 11-7/8 1 13/32 2-1/2 3,995 ISO P9. The ISO P9
10mm-IV 11516P9 .3931 - .3917 10mm x 8mm 3/16 x 13-7/8 3 3/4 6 11,375 option listed on this
IV 12mm-IV 11518P9 .4717 - .4701 12mm x 8mm 3/16 x 13-7/8 3 3/4 6 12,000
page utilizes the same
14mm-IV 11414P9 .5498 - .5489 14mm x 9mm 3/16 x 13-7/8 3 3/4 6 11,375
16mm-V 11516P9 .6292 - .6276 16mm x 10mm 3/4 x 15-1/4 3 3/4 6 11,375
bushings and shims as
V the Standard J-9 metric
18mm-V 11518P9 .7080 - .7064 18mm x 11mm 3/4 x 15-1/4 3 3/4 6 12,000
20mm-VI 11620P9 .7865 - .7845 20mm x 12mm 1 x 19-1/4 3 3/4 6 11,000 broaches listed on the
VI 22mm-VI 11622P9 .8653 - .8633 22mm x 14mm 1 x 19-1/4 4 3/4 6 11,200 previous page.
24mm-VI 11624P9 .9435 - .9430 24mm x 14mm 1 x 19-1/4 4 3/4 6 13,075
25mm-VI 11625P9 .9835 - .9815 25mm x 14mm 1 x 19-1/4 4 3/4 6 13,275 Standard broaches may
be ordered through your
For all metric keyway broaches:
nearest Hassay Savage
EDP Bushings I,II and III Numbers 22106 - 22336 are collared.
industrial distributor for
EDP Bushings IV and V Numbers 22432 - 22572 are plain. off- the-shelf-delivery.
Hassay Savage mm VI Bushing for mm VI Broaches are When ordering from our
available on special order in diameter sizes 85mm to 150mm. standard stock, specify
the EDP number with type
Required shims are supplied for each metric keyway broach. and size as listed in the
When ordering additional or replacement shims, specify EDP appropriate table
number. Shims correspond to metric broach size, not to bushing size.
One Pass Keyway Broaches

One Pass Keyway Broaches American Standard
Keyway Length Pressure
Width Dimensions of Cut Required for
Broach EDP No. Tolerance (in.) Min. Max. Max. I/c (lbs.)
1/8-II 10208-COP** .1252 - .1262 3/16 x 10-3/4 1/4 1-1/2 780
II 5/32-II 10208-COP** .1564 - .1574 3/16 x 10-3/4 1/4 1-1/2 1,370
3/16-II 10210-OP* .1877 - .1887 3/16 x 10-3/4 1/4 1-1/2 1,930
3/16-III 10312-COP** .1877 - .1887 3/8 x 18-1/2 5/16 1-11/16 1,090
III 1/4-III 10316-COP** .2502 - .2512 3/8 x 18-1/2 5/16 1-11/16 1,840
5/16-III 10320-COP** .3127 - .3137 3/8 x 18-1/2 5/16 1-11/16 2,860
3/8-III 10324-OP** .3755 - .3765 3/8 x 18-1/2 5/16 1-11/16 4,030
One Pass Metric Keyway Broaches to ISO H9 Tolerance

Keyway For Standard Length Pressure
Width Millimeter Dim. of Cut Required for
Broach EDP No. Tolerance Keys (in.) Min. Max. Max. I/c (lbs.)
I 3mm-I 11103-OP* .1185 - .1190 3mm x 3mm 1/8 x 8-1/2 1/4 1-1/8 780
4mm-II 11204-COP** .1581 - .1585 4mm x 4mm 1/4 x 10-3/4 1/4 1-1/2 1,370
II
5mm-II 11205-COP** .1975 - .1979 5mm x 5mm 1/4 x 10-3/4 1/4 1-1/2 1,930
6mm-III 11306-COP** .2372 - .2376 6mm x 6mm 3/8 x 18-1/2 5/16 1-11/16 1,090
III
8mm-III 11308-COP** .3159 - .3163 8mm x 7mm 3/8 x 18-1/2 5/16 1-11/16 1,840
* OP designates one-pass, no chamfer ** COP designates chamfer, one-pass
11

Internal Rotary/Punch
Broaches & Plugs
Adjustable & Non Adjustable
Rotary Holders
12
Internal Rotary/Punch Broaches
Hexagonal Rotary/Punch Broaches
8mm - .315 SHANK - AMERICAN 1/2” - .500 SHANK - AMERICAN 3/4” - .750 SHANK - AMERICAN
EDP Hex Depth OAL EDP Hex Depth OAL EDP Hex Depth OAL
No. Size of Cut No. Size of Cut No. Size of Cut
66002 .051” 5/64” 1-1/4” 66106 3/32” 9/64” 1-1/2” 66524 3/8” 1/2” 2-1/2”
66004 1/16” 3/32” 1-1/4” 66107 7/64” 5/32” 1-1/2” 66528 7/16” 1/2” 2-1/2”
66005 5/64” 7/64” 1-1/4” 66108 1/8” 3/16” 1-1/2” 66532 1/2” 5/8” 2-1/2”
66006 3/32” 9/64” 1-1/4” 66109 9/64” 7/32” 1-1/2” 66536 9/16” 3/4” 2-1/2”
66007 7/64” 5/32” 1-1/4” 66110 5/32” 1/4” 1-1/2” 66540 5/8” 3/4” 2-1/2”
66008 1/8” 3/16” 1-1/4” 66112 3/16” 9/32” 1-1/2” 66548 3/4” 7/8” 2-3/4”
66009 9/64” 7/32” 1-1/4” 66114 7/32” 9/32” 1-1/2” 66556 7/8” 7/8” 2-3/4”
66010 5/32” 1/4” 1-1/4” 66116 1/4” 3/8” 1-1/2” 66564 1” 7/8” 2-3/4”
66012 3/16” 9/32” 1-1/4” 66118 9/32” 7/16” 1-1/2”
66014 7/32” 1-1/32” 1-1/4” 66120 5/16 1/2” 1-1/2”
66016 1/4” 3/8” 1-1/4” 66122 11/32” 9/16” 1-1/2”
66018 9/32” 3/8” 1-1/2” 66124 3/8” 9/16” 1-1/2”
66020 5/16” 3/8” 1-1/2” 66126 13/32” 5/8” 2”
66022 11/32” 7/16” 1-1/2” 66128 7/16” 5/8” 2”
66024 3/8” 1/2” 1-1/2” 66130 15/32” 5/8” 2”
66026 13/32” 1/2” 1-1/2” 66132 1/2” 5/8” 2”
66028 7/16” 1/2” 1-1/2” 66134 17/32” 5/8” 2”
66030 15/32” 1/2” 1-1/2” 66136 9/16” 5/8” 2”
66138 19/32” 5/8” 2”
66140 5/8” 3/4” 2”
Tin coating available 66142 21/32” 3/4” 2”
66144 11/16” 3/4” 2”
66146 23/32” 3/4” 2”
66148 3/4” 7/8” 2”
8mm - .315 SHANK - METRIC 1/2” - .500 SHANK - METRIC
EDP Hex Depth OAL EDP Hex Depth OAL
No. Size of Cut No. Size of Cut
662013 1.3mm 3/32” 1-1/4” 66302 2mm 5/32” 1-1/2”
662015 1.5mm 3/32” 1-1/4” 663025 2.5mm 5/32” 1-1/2”
66202 2mm 7/64” 1-1/4” 66303 3mm 3/16” 1-1/2” Applications:
662025 2.5mm 5/32” 1-1/4” 66304 4mm 1/4” 1-1/2”
66203 3mm 3/16” 1-1/4” 66305 5mm 5/16” 1-1/2” For use with screw machines, CNC
66204 4mm 1/4” 1-1/4” 66306 6mm 3/8” 1-1/2” turning machines and arbor press-
66205 5mm 5/16” 1-1/4” 66307 7mm 1/2” 1-1/2”
66206 6mm 3/8” 1-1/4” 66308 8mm” 1/2” 1-1/2” es. For use in automotive, aero-
66207 7mm 3/8” 1-1/2” 66309 9mm 1/2” 1-1/2” space, medical and other various
66208 8mm 3/8” 1-1/2” 66310 10mm 9/16” 1-1/2”
66209 9mm 3/8” 1-1/2” 66311 11mm 9/16” 2” fields.
66210 10mm 1/2” 1-1/2” 66312 12mm 5/8” 2”
66211 11mm 1/2” 1-1/2” 66314 14mm 5/8” 2”
66212 12mm 1/2” 1-1/2” 66315 15mm 5/8” 2” Other Shanks, Metric, Square,
66316 16mm 5/8” 2” Torx© Octagon & Spline Forms
Tin coating available 66317 17mm 7/8” 2”
66318 18mm 7/8” 2” Available, Please Call.
66319 19mm 7/8” 2”
Square Rotary/Punch Broaches

8mm - .315 SHANK - AMERICAN 1/2” - .500 SHANK - AMERICAN 3/4” - .750 SHANK - AMERICAN
EDP Hex Depth OAL EDP Hex Depth OAL EDP Hex Depth OAL
No. Size of Cut No. Size of Cut No. Size of Cut
68004 1/16” 1/8” 1-1/4” 68106 3/32” 9/64” 1-1/2” 68532 1/2” 5/8” 2-1/2”
68006 3/32” 9/64” 1-1/4” 68108 1/8” 3/16” 1-1/2” 68536 9/16” 3/4” 2-3/4”
68008 1/8” 3/16” 1-1/4” 68110 5/32” 1/4” 1-1/2” 68540 5/8” 3/4” 2-3/4”
68010 5/32” 1/4” 1-1/4” 68112 3/16” 9/32” 1-1/2” 68548 3/4” 7/8” 2-3/4”
68012 3/16” 9/32” 1-1/4” 68114 7/32” 11/32” 1-1/2”
68014 7/32” 11/32” 1-1/4” 68116 1/4” 3/8” 1-1/2”
68016 1/4” 3/8” 1-1/2” 68118 9/32” 7/16” 1-1/2”
68018 9/32” 3/8” 1-1/2” 68120 5/16” 1/2” 1-1/2”
68020 5/16” 3/8” 1-1/2” 68122 11/32” 9/16” 1-1/2”
68022 11/32” 3/8” 1-1/2” 68124 3/8” 5/8” 2”
68024 3/8” 3/8” 1-1/2” 68128 7/16” 5/8” 2”
68132 1/2” 5/8” 2”
68136 9/16” 3/4” 2”
68140 5/8” 7/8” 2”
13

Adjustable Rotary Broach Holders
Accepts Internal Hex & Square Rotary Broaches Holders
FOR BROACHES WITH 8mm - .315 SHANK FOR BROACHES WITH 3/4” - .750 SHANK
EDP OAL Shank Shank Broach EDP OAL Shank Shank Broach
No. Dia. Length Shank Depth No. Dia. Length Shank Depth
P-67040 3-27/64” 5/8” 1-1/2” 9/16” P-67072HDS 7-9/16” 3” 1-1/2” 1.250”
P-670485 3-59/64” 3/4” 2” 9/16” P-67076HD 7-9/16” 3” 1-3/4” 1.250”
FOR BROACHES WITH 1/2” - .500 SHANK

EDP OAL Shank Shank Broach
No. Dia. Length Shank Depth
P-67048 4-17/32” 3/4” 2” 0.742”
P-67064 4-17/32” 1” 2” 0.742”
P-67068 5-17/32” 1 1/4” 3” 0.742”
P-67072 5-17/32” 1 1/2” 3” 0.742”
Applications
Rotary/Punch Broaches can be the work piece or vise versa as Punching
used in a variety of machines to described below: Versus Rotary
cut polygons in blind holes: Any Broaching:
type of CNC or manual turning, Broaching a Rotating Work Many applica-
milling, drilling or screw Piece: In a turning or screw tions can be
machine. The practical forming machine, the holder is mounted achieved
length of a rotary/punch broach- stationary while its internal live without the
ing is usually up to 1-1/2 times spindle and the broach rotates rotary broach
the size of the broach (measured after contact with the rotating holder. For
across flats). work piece (Diagram A), At the the purpose
appropriate feed, the workpiece of merely
1˚
Rotary Broach Holders: For opti- is “sheared” by the pressure of punching a
mal tool life in large production the broach through a wobbling polygon into
settings these broaches are used type action producing the poly- Diagram A an existing
in Rotary Broach Holders. gon shape desired. pilot hole,
Holders and broaches are sold sepa- these broach-
rately and available from stock for Broaching a Stationary Work es have suc-
immediate delivery. These holders Piece: In a milling or drilling cessfully been
are for use on any type CNC or machine, the holder is mounted used with
manual turning, milling, drilling into and rotates with the universal
or screw machine. The holder machine spindle while its inter- machining
has an internal live spindle, nal live spindle along with the methods.
which holds the end cutting broach remains stationary upon
broach tool. The centerline of contact with the stationary work
the cutting tool is offset at 1° piece (Diagram B). While the For
1˚
from the centerline of the work machine spindle is rotating, the Recommended
piece. This causes the broach to broach’s pressure shears the Use, See Next
wobble creating a shearing effect polygon shape into the work Diagram B Page.
as the broach is advanced into piece (wobbling type action).
14
Use Recommendations
Part Preparation: The diameter of size of the broach in inches for a
the pre-drilled hole should be 1-2% feed rate in IPR units. For exam-
larger than the measurement across ple the feed rate for a 1/4”
the flats on the broach. Drill the rotary/punch broach would be
hole as deep as possible for chip 0.16 x .250 = .004”/rev.
clearance. Countersink with a 90°
lead chamfer slightly larger than Coolant: The amount of heat gen-
the largest dimension of the broach erated is minimal. Normal coolant
face (distance across points). or cutting oil should be applied on
the tip of the broaching tool prior
Centering the Broach: The most to contacting the work piece and
critical component in running these not inside of the work piece pilot
tools is having the broach centered hole. Trapped fluid may not be
as close as possible to the centerline able to escape, causing inability to
of the work piece. Improper center- broach to full depth.
ing will cause uneven hole configu-
rations, oversize holes, spiraling, Broach Tool Material: Broaches
and excessive cutter/holder wear. are customarily manufactured
It is necessary to align the end of from M-2 high-speed steel. This
the broach tool to the centerline of material provides the required
the work piece diameter by means edge toughness for standard
of adjusting the screws located on operations, which do not generate
the sides of the holder. Alignment enough heat to effect tool life in
instructions are included with pur- machining most metals. However,
chase of the tool holder. for broaching materials such as
ductile iron, tool steel, stainless
Speeds and Feeds: Rotational steels, titanium alloys, or nickel-
speed (RPM) has very little effect cobalt alloys, a cobalt or PM-4
on cutting speed and tool life. We powdered metal broach would be
recommend starting at 800 RPM recommended for optimal tool
with a feed rate of .016 times the life. Coatings are also available.
You can successfully broach these shapes & others

with Hassay Savage Tools
To request a quote please copy and fax this page to 1-800-605-2442 , or 613-836-9070,
BROACH REQUIREMENTS CONTACT INFORMATION
Size/Shape Depth of Cut Contact Name
Tolerance +/- Company Name
Desired Broach Shank Size Address
Material to be Machined Phone # Fax #
Type of Machine Email
Type of Holder
15

Rotary Broaching Set-Up Plugs
Rotary Broaching Set-Up Plug Procedure
Things You Need to Know for the Perfect Set-up
8mm Metric Shank
Plug Shank Depth Overall
EDP Diameter Diameter of Plug Length OAL
Size No. (- .001 inches) (- .0050 inches) (inches) (inches)
1/8 67008 .13 8mm 5/16 1-1/4
3/16 67012 .192 8mm 5/16 1-1/4
1/4 67016 .254 8mm 5/16 1-1/2
3/8 67024 .385 8mm 1/2 1-1/2
1/2 67032 .51 8mm 1/2 1-1/2
The process of setting up and

1/2” American Standard Shank
centering a rotary broach holder Plug Shank Depth Overall
EDP Diameter Diameter of Plug Length OAL
for conventional blind hole Size No. (- .001 inches) (- .0050 inches) (inches) (inches)
broaching can sometimes be 3/16 67112 .192 .500 5/16 1-1/2
tedious and difficult for first time 1/4 67116 .254 .500 5/16 1-1/2
3/8 67124 .385 .500 1/2 1-1/2
users as well as for the experi- 1/2 67132 .51 .500 1/2 2
enced operator. We will try to 5/8 67140 .64 .500 1/2 2
make that experience as effortless
as possible, and by developing
some simple set-up proce- 3/4” American Shank
dures for you, we are tak-
Plug Shank Depth Overall
ing all of the guesswork EDP Diameter Diameter of Plug Length OAL
out of the equation. Size No. (- .001 inches) (- .0050 inches) (inches) (inches)
Please read through our 3/8 67524 .385 .750 1/2 2-1/2
following application 1/2 67532 .51 .750 1/2 2-1/2
5/8 67540 .64 .750 3/4 2-1/2
notes and realize how a 3/4 67540 .77 .750 3/4 2-1/2
somewhat challenging
set-up can be made easy. 4. Drill and ream or bore a hole sure the broach is bottomed out in
.001 - .002 larger for the set-up plug the holder, the same as the set-up
diameter in the material on your plug in Step 2.
Set-up Made Easy machine, with a 90° lead chamfer to
11. Re-center the rotary broach by
allow for alignment.
1. Start by placing the rotary tool holder indicating the same as Step 3 and
in the turret of a lathe or the tool start broaching.
5. Loosen the 2 clamp screws and the
holder of a milling machine, depend- We can also supply you with custom
6 adjustment screws on the flange
ing on your application, which “specific turned diameters” for your exact
portion of the body to the shank of
machine best fits your process drill and bore size when repeatable set-
the rotary broach holder.
needs. ups are required for your job on a contin-
6. Advance the holder with the inserted
uous basis. These will all come with the
2. Mount our centering plug in the plug into the reamed hole.
standard lengths and shank diameters
spindle of the rotary broach tool 7. With the plug still engaged in the of: 8mm, .500, and .750. Contact our
holder and take care that the plug is hole, tighten the 2 clamp screws customer service department at 800-
bottomed out in the spindle before 247-2024 for pricing and 24 hour
tightening. 8. Then tighten the 6 adjusting screws.
delivery service.
3. Center it on the tool shank with the 3 9. Back the holder out of the reamed hole. Above are some listings of the stan-
adjustment screws that are on the dard diameter gauge-plug with specifica-
10. Remove the set-up plug and replace
spindle using a dial indicator. tions that you can purchase from stock
with the rotary broach tool, making
Reference our hex broaching inventories to use in standard holders.
chapters on our website for visuals of
the set-up process:
.
16
Adjustable Rotary Broaching
What are the differences between rotary, Swiss/wobble,
punch and index?
Rotary dure will be performed on a a partial for of the shape that is to
The tool shape is cut into the cus- Computer Numerical Control be generated. Once hole prepar-
tomer's part with spindle turning Turning Center. tion is completed, the tool form is
when using a rotary holder sys- The broaching holder serves generated on a Swiss type CNC
tem. two functions: It holds the broach machine by making imprints of
tool in a free spinning bearing; the tool to the proper depth while
and, it places the broach tool at a the part is indexed properly to
1° angle relative to the centerline create the full form desired.
of the workpiece.
There are two types of
commonly used holders:
1°
• Adjustable Rotary Broach
holder H = Hex Size
The Rotary Holders: 1.4 x H
With materials today that make
up these component parts ranging
from difficult to machine Cutting Principle
Titanium 6AL 4V and stainless The tool is held at a 1° angle rela-
steels like 17-4 PH or 18-8 PH, we tive to the part centerline and has
offer solutions that maintain con- a 1° 30” clearance angle built in.
sistent process control and longer The face of the broach tool is the
Coaxial Indicator
tool life in the running time. We pivot of the 1° angle and is placed
offer rotary broaching holders in a on centerline with the part. As
range from typical commerical Swiss Style or Wobble the tool comes in contact with the
applications, to a high end Swiss • Swiss Non-Adjustable Rotary part, friction drives the broach to
made rotary holder system for Broach Holder rotate synchronously. The cutting
Swiss type CNC machining. edge is kept on center and the rest
The commercial grade system is The tool shape is cut into the of the tool oscillates around the
an adjustable tool that has to be customer's part with spindle part centerline with a wobble
set-up for centerline by making the turning when using a rotary effect. With the faces of the tool
holder and spindle run on zero holder system. This is typical and part at a relative 1° angle,
run-out at the point of the tool. when used on a vertical machin- only the leading point of the tool
We offer holders that will do ing center. is cutting and not the entire pro-
.060 (1,5mm) hex to 1.000” file. The wobble effect moves the
(25,4mm) hex holes in steel. Punch/Index leading edge to rotate in and out
Hex Rotary Broaching can be The shape is cut with the spindle of the cut like a cam. It shears the
performed on multiple machin- locked in a stationary position, shape into the part with a scallop-
ing applications, for instance and the broach is then punched ing effect as it advances forward.
CNC machining centers or into the customer's part. This reduces the required thrust
transfer machines. For the pur- Index- A broaching process that force up to 80% when it is at the
pose of this material the proce- involves a stationary spindle and optimum feed.
17

How to Set Up Adjustable Rotary Broach
Holder for CNC Machining
Adjustable Rotary Broach Holder Set Up
To complete this procedure you 4. Tighten the two set screws to screws. Each
will need the required tooling: secure the hex broach in place. one of these
Broach Holder; Hex Broach or Retrieve the indicator gauge and set screws
set up plug, Magnetic base position the tip of the gauge on the acts as a
adjustable indicator for bench set end of the broach. Zero the indica- pivot point for
up; Coaxial indicator gauge for tor before gauging the set up. the face of
CNC machine set up the holder.
Using an allen
The set up can be completed on wrench,
the machine, but for efficiency we loosen or
recommend completing it off-line. tighten each
one accord-
1. First position the shank of the
ingly.
holder into the end of the colleted
fixture. If necessary, turn the 10. Spin complete holder then
handwheel on the fixture to in- regauge with the indicator and
crease or decrease the size of continue to make the necessary
the opening to adjust to the size adjustments until the desired
of the shank on the rear of the reading between .001 - .002 is
holder. met. Retighten the two larger
allen screws.
5. Turn the handwheel on the fix-

ture while watching the indicator
to determine if the broach is
aligned on center with the shank 11. Remove the hex broach
of the holder. from the holder by loosening
6. Readings between .001 and the two set screws. Reposition
.002 are acceptable limits. the orienta-
Readings above .002 are unac- tion of the
ceptable an will require addi- broach with
tional adjustments to the holder. the hex head
facing out.
7. There are several adjustment Tighten the
screws on the holder that may set screws.
2. Insert the end of the holder need to be adjusted to set the
into the fixture and turn the hand- centerline. 12. This completes the set up of
wheel to secure the holder. 8. There are two large allen the rotary broach holder. Now
screws that secure the face of the holder can be installed into
3. Loosen the two set screws on the appropriate CNC machine
the front of the holder. Insert the the holder together. Using an
allen wrench, loosen each of for operations.
hex broach into the front of the
holder with the circular end fac- these. Note: See our set-up procedure
ing out for ease of indicating, or 9. Next to each of these large on our website course videos-
use set-up plug. allen screws are three set “Hex rotary broaching.”
18
Rotary and Index Broaching
Market and Process Updates
Improved Technologies for Medical Orthopedic
Products & Components
Rotary and index broaching in as well as a full array of other com-
our industry today is becoming a ponent equipment that is used to
more consistent part of the manu- support the entire field of medi-
facturing process as CNC cine. Our product is used to
machines become more sophisti- hold hex bone screw toler-
cated. The Swiss CNC equipment ances of +/- .0005
today can even compensate for (0,012mm) for size-- which is
concentricity of centerline to hole difficult to maintain-- in conven- industry is Special Tolerance
location, which is a major tional manufacturing environ- and Special lengths for a variety
improvement over machines of ments. To do this, we will main- of solutions specific to our cus-
only a few years ago. The compo- tain a ± .0002 (0,005mm) tolerance tomer. 60% of our manufactured
nents built in the medical fields on the actual broach. Typical hex tooling is considered a special.
today require incredibly close tol- sizes range from: 1,5mm, 2,5mm, The amount of “special” tools
erances and strict quality controls 3mm, 3,5mm, 4,5mm and 5mm. manufactured every day in our
like “6-sigma” to get their prod- We have developed a medical hex plant is more than our standard
ucts to market broach full form range in cobalt line in the orthopedic market.
based high-speed steel from stock Hassay Savage special tooling is
inventories that will allow a cus- typically delivered in 5-7 days to
tomer to get his tools the next day our customer’s specifications.
Our CNC-CBN ground tools are
when delivery is critical. always consistent tool to tool.
In addition, the majority of
The Rotary
Broach Tooling: our tooling supplied in this
We have been insturmental in Swiss Style Broach

serving many sectors of the med-
ical field today as a high quality Hexagonal Rotary/Punch Broaches
manufacturer of precision broach-
ing tools to make hex and square .315 shank - American .315 shank - Metric
forms in orthopedic bone screws,
EDP EDP Depth EDP EDP Depth
No. No. Hex of No. No. Hex of
M-2 PM M-4 Size Cut OAL M-2 PM M-4 Size Cut OAL
76002 77002 .051 5/64 28mm 762015 772015 1.5mm 3/32 28mm
76004 77004 1/16 3/32 28mm 76202 77202 2mm 7/16 28mm
76005 77005 5/64 7/64 28mm 762025 772025 2.5mm 5/32 28mm
76006 77006 3/32 9/64 28mm 76203 77203 3mm 3/16 28mm
76007 77007 7/64 5/32 28mm 762035 772035 3.5mm 3/16 28mm
76008 77008 1/8 3/16 28mm 76204 77204 4mm 1/4 28mm
76009 77009 9/64 7/32 28mm 762045 772045 4.5mm 1/4 28mm
76010 77010 5/32 1/4 28mm 76205 77205 5mm 5/16 28mm
76012 77012 3/16 9/32 28mm 76206 77206 6mm 3/8 28mm
76014 77014 7/32 11/32 28mm
76016 77016 1/4 3/8 28mm
19

Non-Adjustable Rotary Broach Holders
Swiss Style Holders

• No Center Indicating • Built In Wobble Cutting
Required Feature 1° Angle
• Smaller Head Diameter • Heavy Duty Bearing Takes
Eliminates Interference 2250lbs. Pushing Force
• Longer Shank Can Be Cut • Swiss Made Quality High-
To Proper Length Precision
2160 Series
• Short Head Length For • Fits Most For Swiss Type
Limited Back Work Space & Gang Machines
2160 Series Holders

Holds 8mm shank broaches, max. push force 2250 lbs.
Part No. Inch D L Part No. Metric D L
HSP-2160-158-038 .625 1.50 HSP-2160-120-038 12 38
HSP-2160-190-100 .750 4.00 HSP-2160-140-038 14 38
HSP-2160-254-120 1.00 4.75 HSP-2160-160-038 16 38
HSP-2160-200-100 20 100
HSP-2160-220-100 22 100
HSP-2160-250-120 25 175
Self Centering
Designed for CNC machines, the new 2100 Series
Broach Holder meets the challenge for faster and
easier setup by placing the broach tool on center
and eliminating the need to indicate the holder.
The cylindrical shank design with Weldon
Notch makes the 2100 Series perfect for lathe or
machining center applications.
2100 Series
2100 Series Holders
Holds 8mm shank broaches, max. push force 900 lbs.
Part No. Inch D L Part No. Metric D L
HSP-2100-58 15.87 38 HSP-2100-16 16 38
HSP-2102 19.05 38 HSP-2101 20 38
HSP-2104 25.4 58 HSP-2103 25 50
Besides the focus, effort and con- components, and micro precision active and integral role in employing
centration that we have put into the systems that require high precision high performance results for those
medical field over the years working tolerance and quality. customers who demand not only
with most of the highly respected It is interesting to note here that quality, but also consistent tool life
manufacturers, we have put that all of our product line groups for that keeps their machines running
same undivided attention into other Hassay Savage and Magafor com- longer.
areas of micro-manufacturing includ- panies: www.hassay-savage.com;
ing automotive and aircraft micro www.magaforusa.com; play an
20
CNC-Single Point Keyway Broaches
A CNC Broaching Alternative Keyway Range-
1/8 - 1/2”
4mm - 12mm
Broaching keyways on CNC The advantages:
machines today is as common as • Complete the part on one machine • No bushing guide
turning a part. It will eliminate • Only way to keyway a blind hole required
part handling and improve your • Cut down on set-up time • No hydraulic
control when you design your • Improve your process press or pull
process to incorporate short effec- • Become more flexible with required
machining • No additional
tive nibbling broaches that take the
• Manage small lot production operator needed
place of much longer tools and
• Use cost effective standard tooling
sometimes timely set up on sec-
ondary machines.
We offer a choice of tooling below that accommodates the most frequently
Blind hole and through hole made keyways in our markets today for both US and export consumption.
CNC keyway broaching with stan- We can easily accommodate other keyway sizes as well as those listed. Call
dard tools that are off the shelf, us for recommendations on your specific job needs.
will give you a profitable alterna-
Shank Overall Max.
tive and save you time. EDP Tolerance Diameter Length OAL LOC
Blind hole or through hole CNC Size No. (inches) (inches) (inches) (inches)
keyway broaching is achieved 1/8 69008 .1265 .625 3.75 1.50
through the use of single point nib- 4mm 69004 .159 .625 3.75 1.50
5mm 69005 .198 .625 3.75 1.50
bling cutters that are designed with 6mm 69106 .238 .875 4.50 2.00
two separate cutting surfaces at 180° 1/4 691 16 .252 .875 4.50 2.00
apart. The one piece construction is 5/16 69120 .314 .875 4.50 2.00
8mm 69108 .317 .875 4.50 2.00
created on a high speed tooling
3/8 69224 .377 1 4.50 2.00
blank that is a common size round 10mm 69210 .396 1 4.50 2.00
shank with ground timing flats to 12mm 69212 .4745 1 4.50 2.00
align the keyway for timing to the 1/2 69232 .502 1 4.50 2.00
part it is broaching. These tools will the keyway at a speed of 10 - 30 in/min Things That You
offer long tool life, and can be easily and an in-feed of .003 -.005 depth per
Should Know:
sharpened many times for extended pass, using a flood coolant for lubrica-
• Standard tooling will come with
tool life. Ideally designed for either tion during the cut. The in-feeding cycle common shank diameters.
CNC lathe or CNC vertical machin- is repeated until the desired depth of
• The keyway size and length or
ing centers, these tools can get the the keyway is achieved. Chips can be depth of cut will determine the
job done quickly and effectively: removed from the bottom of the hole in shank size.
• For a CNC lathe, the tool is mounted a couple of ways: • Strength and rigidity in the set-
directly into the turret on centerline • If the hole is a blind hole bore, remove up will give you longer tool life.
while a setscrew-locking holder will the chips by either prior trepanning the • Consider using the larger shank
lock the tool in place and position. bottom of the keyway area and allow size to process your jobs.
• For a CNC vertical machining center, chips to fall away
• Keyway production will achieve
a collet will hold the tool shank and • Or pre-drill a hole from the outside to excellent finishes and better
provide timing orientation. the inside of the part at the bottom of accuracy.
the keyway location.
With the spindle locked, the broach • You can design and create your
can be brought inline with the pre- • With a through hole, you can broach own special tool with our help.
right through, but do not disengage Call or see our website chapter
prepared bore diameter and chamfer with the part, and simply de-burr the on Single Key Broaching.
lead of the part to start broaching keyway upon completion.
21

Standard Inch Square Push
American Standard
Dimension Pressure
Size EDP Across Pilot Drill Broach Length of Cut for
Square No. Tolerance Corners Diam. Size Length Min. Max. Max. L/C lbs.
1/8 13008 .1250 - .1260 .1750 - .1770 .1280 #30 4-5/8 3/16 1/2 700
5/32 13010 .1565 - .1575 .2180 - .2200 .1585 #21 5-5/8 1/4 1/2 800
3/16 13012 .1880 - .1890 .2620 - .2640 .1930 #10 5-11/16 1/4 5/8 1,120
7/32 13014 .2190 - .2200 .3050 - .3070 .2275 #1 6-7/8 1/4 3/4 1,580
1/4 13016 .2505 - .2515 .3500 - .3520 .2651 17/64 7 1/4 3/4 1,740
9/32 13018 .2815 - .2825 .3930 - .3950 .2964 19/64 7-1/4 3/8 1 2,300
5/16 13020 .3130 - .3140 .4370 - .4390 .3276 21/64 8-1/8 3/8 1 2,630
11/32 13022 .3440 - .3450 .4810 - .4830 .3589 23/64 9-5/8 3/8 1-1/4 3,050
3/8 13024 .3755 - .3765 .5230 - .5250 .3901 25/64 9-7/8 3/8 1-1/4 3,625
13/32 13026 .4065 - .4075 .5680 - .5700 .4214 27/64 10-7/8 1/2 1-3/8 5,200
7/16 13028 .4385 - .4395 .6110 - .6130 .4526 29/64 11-3/8 1/2 1-3/8 5,700
15/32 13030 .4690 - .4700 .6560 - .6580 .4995 38719 12-1/2 1/2 1-3/8 5,900
1/2 13032 .5005 - .5015 .6970 - .6990 .5307 17/32 12-5/8 1/2 1-3/8 6,000
9/16 13036 .5630 - .5640 .7860 - .7880 .5932 19/32 14-7/8 1/2 1-1/2 6,200
5/8 13040 .6260 - .6270 .8710 - .8730 .6557 21/32 16-13/16 5/8 1-5/8 7,100
11/16 13044 .6885 - .6895 .9610 - .9630 .7495 38780 18-1/2 5/8 1-5/8 7,300
3/4 13048 .7510 - .7520 1.0450 - .10470 .8120 13/16 18-7/8 5/8 1-5/8 8,600
7/8 13056 .8765 - .8775 1.2280 - 1.0300 .9370 15/16 22-3/4 1/2 2 12,000
1 13064 1.0020 - 10030 1.4030 - 1.4050 1.0932 1-3/32 24-1/2 1/2 2 12,500
Standard Metric Square Broaches

Dimensions Pilot Broach Length of Cut
Size Tolerances* Across Corners Diameter Drill Size Length (inches)
Square EDP No. (inches) (inches) -.0005 (inches) mm (inches) Min. Max.
4mm 17001 .1580 - .1585 .2080 - .2090 .1655 4.2 5-9/16 5/16 5/8
5mm 17002 .1973 - .1983 .2645 - 2655 .2047 5.2 6-7/8 3/8 3/4
6mm 17003 .2367 - .2377 .3295 - .3300 .2500 6.35 7 3/8 3/4
8mm 17004 .3155 - .3165 .4405 - .4410 .3267 8.3 8-3/16 7/16 7/8
10mm 17005 .3942 - .3952 .5435 - .5445 .4057 10.3 10-7/8 1/2 1
12mm 17006 .4729 - .4739 .6540 - .6550 .4921 12.5 12-1/2 5/8 1-1/4
14mm 17007 .5517 - .5527 .7700 - .7710 .5905 15.0 14-7/8 3/4 1-1/2
16mm 17008 .6310 - .6320 .8780 - .8790 .6693 17.0 16-13/16 7/8 1-3/4
18mm 17009 .7092 - .7102 .9880 - .9890 .7874 20.0 18-1/2 7/8 1-3/4
20mm 17010 .7879 - .7889 1.0990 - 1.100 .8661 22.0 18-7/8 7/8 1-3/4
22mm 17011 .8666 - .8676 1.2110 - 1.2120 .9448 24.0 23-1/4 7/8 1-3/4
24mm 17012 .9454 - .9464 1.3170 - 1.3180 1.0236 26.0 24-9/16 7/8 1-3/4
25mm 17013 .9848 - .9858 1.3730 - 1.3740 1.0630 27.0 24-9/16 7/8 1-3/4
Standard Full Square Push

Dimension Pressure
Size EDP Across Pilot Drill Broach Length of Cut for
Square No. Tolerance Corners Diam. Size Length Min. Max. Max. L/C lbs.
3/16 14012 .1880 - .1890 .2628 - .2632 .1870 3/16 6-1/4 3/16 1/2 1,200
1/4 14016 .2505 - .2515 .3513 - .3517 .2495 1/4 8-5/8 1/4 5/8 1,600
5/16 14020 .3120 - .3140 .4375 - .4380 .3120 5/16 10-1/4 1/4 3/4 2,300
3/8 14024 .3755 - .3765 .5243 - .5247 .3745 3/8 12-1/4 3/8 1 3,750
1/2 14032 .5005 - .5015 .6980 - .6990 .4995 1/2 14-7/16 3/8 1 5,000
22
Hexagonal Push Broaches
American Standard
Pressure
Hex EDP Diagonal Pilot Drill Broach Length of Cut for
Size No. Tolerance Dimension Diam. Size Length Min. Max. Max. L/C lbs.
1/8 12008 .1255 - .1260 .1450 - .1470 .1245 1/8 4-5/8 3/16 3/8 120
5/32 12010 .1565 - .1570 .1800 - .1820 .1557 5/32 5-1/2 1/4 1/2 340
3/16 12012 .1880 - .1890 .2145 - .2155 .1870 3/16 5-9/16 1/4 5/8 520
7/32 12014 .2190 - .2200 .2500 - .2520 .2182 7/32 6 1/4 3/4 890
1/4 12016 .2505 - .2515 .2865 - .2875 .2495 1/4 6-1/2 1/4 3/4 1,250
9/32 12018 .2815 - .2825 .3220 - .3240 .2807 9/32 7-3/4 3/8 1 1,650
5/16 12020 .3130 - .3140 .3580 - .3590 .3120 5/16 8-1/4 3/8 1 2,175
11/32 12022 .3440 - .3450 .3950 - .3970 .3432 11/32 8-1/4 3/8 1-1/4 3,500
3/8 12024 .3755 - .3765 .4300 - .4310 .3745 3/8 9 3/8 1-1/4 3,700
13/32 12026 .4065 - .4075 .4670 - .4690 .4057 13/32 10 1/2 1-3/8 4,100
7/16 12028 .4385 - .4395 .5020 - .5030 .4370 7/16 10-3/4 1/2 1-3/8 4,575
15/32 12030 .4690 - .4700 .5390 - .5410 .4682 15/32 12-3/8 1/2 1-3/8 4,700
1/2 12032 .5005 - .5015 .5740 - .5750 .4995 1/2 12-1/2 1/2 1-3/8 5,300
9/16 12036 .5630 - .5640 .6480 - .6500 .5620 9/16 14-1/4 1/2 1-1/2 6,700
5/8 12040 .6260 - .6270 .7170 - .7185 .6245 5/8 16-7/8 5/8 1-5/8 7,250
11/16 12044 .6880 - .6890 .7930 - .7950 .6870 11/16 17 5/8 1-5/8 9,300
3/4 12048 .7510 - .7520 .8610 - .8625 .7495 3/4 17-7/8 5/8 1-5/8 13,500
7/8 12056 .8755 - .8765 1.0060 - 1.0075 .8745 7/8 18-7/8 5/8 1-5/8 18,500
1 12064 1.0020 -10030 1.1520 - 1.1530 .9995 1 19-7/8 5/8 1-5/8 20,050
Metric
Pressure
Hex EDP Diagonal Pilot Drill Broach Length of Cut for
Size No. Tolerance Dimension Diam. Size Length Min. Max. Max. L/C lbs.
4mm 12104 .1580 - .1585 .1820 - .1830 .1575 4.0 5-1/2 1/4 1/2 340
5mm 12105 .1973 - .1983 .2270 - .2280 .1968 5.0 6 1/4 3/4 890
6mm 12106 .2367 - .2377 .2730 - .2740 .2362 6.0 6-1/2 1/4 3/4 1,250
7mm 12107 .2760 - .2770 .3180 - .3190 .2756 7.0 7-3/4 3/8 1 1,650
8mm 12108 .3155 - .3165 .3634 - .3644 .3150 8.0 8-1/4 3/8 1 2,175
10mm 12110 .3942 - .3952 .4543 - .4553 .3937 10.0 10 1/2 1 4,100
12mm 12112 .4729 - .4739 .5452 - .5462 .4724 12.0 12-3/8 1/2 1-3/8 4,700
14mm 12114 .5517 - .5527 .6332 - .6342 .5512 14.0 14-1/4 1/2 1-3/8 6,700
16mm 12116 .6310 - .6320 .7248 - .7258 .6290 16.0 16-7/8 5/8 1-1/2 7,250
18mm 12118 .7092 - .7102 .8150 - .8180 .7087 18.0 17 5/8 1-5/8 9,400
20mm 12120 .7879 - .7889 .9049 - .9059 .7874 20.0 17-7/8 5/8 1-5/8 14,150
22mm 12122 .8666 - .8676 .9958 - .9968 .8661 22.0 18-7/8 5/8 1-5/8 18,500
24mm 12124 .9454 - .9464 1.0868 - 1.0878 .9449 24.0 19-7/8 5/8 1-5/8 20,500
25mm 12125 .9848 - .9858 1.1323 - 1.1333 .9842 25.0 19-7/8 5/8 1-5/8 22,000
*Tolerance considerations are based on preferred metric limits and fits--ANSI B4.2-1978
NOTES: Hassay Savage Special Square and Hexagon Include the following data:
standard square and hexagon Broaches: If your application Hole: dimensions before and
broaches are HSS push type; cannot be handled with the stan- after broaching, with tolerances,
designed for one-pass finishing dard hexagon broaches listed, and whether cast, drilled or
when used with arbor or send us a sample or print of the reamed; length required.
hydraulic press, or vertical part to be broached. Material: specifications, and
broaching machine. whether bar, cast or forged
stock; appropriate hardness
before broaching.
23

Davis Style Keyseating Broaches
American Standard
Keyway Width Dimensions
Hex EDP Tolerance Body Width x Length of Cut
Size No. (inches) Height x Length Min. Max.
1/16 10701 .0625 - .0635 3/16 x 3/8 x 16 5/8 1-7/8
3/32 10702 .0937 - .0947 3/16 x 3/8 x 16 5/8 1-7/8
1/8 10703 .1252 - .1262 3/16 x 7/16 x 16 5/8 1-7/8
5/32 10704 .1564 - .1574 3/16 x 1/2 x 16 5/8 1-7/8
3/16 10705 .1877 - .1887 3/16 x 9/16 x 16 5/8 1-7/8
3/16 10706 .1877 - .1887 3/16 x 3/4 x 20 5/8 3-1/8
1/4 10707 .2505 - .2515 1/4 x 3/4 x 16 5/8 1-5/8
1/4 10708 .2505 - .2515 1/4 x 3/4 x 20 5/8 3-1/8
5/16 10709 .3127 - .3137 5/16 x 7/8 x 16 1-1/16 3-3/16
5/16 10710 .3127 - .3137 5/16 x 7/8 x 20 1-1/16 5-3/16
3/8 10711 .3755 - .3765 3/8 x 7/8 x 16 1-1/16 3-3/16
3/8 10712 .3755 - .3765 3/8 x 7/8 x 20 1-1/16 5-5/16
7/16 10713 .4380 - .4390 7/16 x 1 x 16 1-1/16 3-3/16
7/16 10714 .4380 - .4390 7/16 x 1 x 20 1-1/16 5-3/16
1/2 10715 .5006 - .5016 1/2 x 1 x 20 1-1/16 5-3/16
9/16 10716 .5630 - .5640 9/16 x 1 x 20 1-1/16 5-3/16
5/8 10717 .6260 - .6270 5/8 x 1 x 20 1-1/16 5-3/16
3/4 10718 .7515 - .7525 3/4 x 1 x 20 1-1/16 5-3/16
7/8 10719 .8765 - .8775 3/8 x 1 x 20 1-1/16 5-3/16
1 10720 1.0015 -10025 1 x 1 x 20 1-1/16 5-3/16
Metric
Keyway Width Dimensions
Hex EDP Tolerance Body Width x Length of Cut
Bore Size No. (inches) Height x Length Min. Max.
Size 2mm 11701 .0787 - .0792 3/16 x 3/8 x 16 5/8 1-7/8
3mm 11702 .1181 - .1186 3/16 x 3/8 x 16 5/8 1-7/8
4mm 11703 .1575 - .1580 3/16 x 7/16 x 16 5/8 1-7/8
Hassay Savage HSS keyseating pull 5mm 11704 .1968 - .1973 5mm x 9/16 x 16 5/8 1-7/8
broaches are manufactured similar to 5mm 11705 .1968 - .1973 5mm x 3/4 x 20 5/8 3-1/8
the Davis AF series cutters. Our cut- 6mm 11706 .2362 - .2367 6mm x 3/4 x 16 5/8 1-7/8
ter bars have 10° rake face, 5° back- 6mm 11707 .2362 - .2367 6mm x 3/4 x 20 5/8 3-1/8
off and 2° side-relief on all teeth. 8mm 11708 .3150 - .3155 8mm x 7/8 x 16 5/8 3-3/16
These broaches may be used on 8mm 11709 .3150 - .3155 8mm x 7/8 x 20 1-1/16 3-3/16
Davis model 4, 5, and15 machines. 10mm 11710 .3937 - .3942 10mm x 7/8 x 16 1-1/16 5-5/16
Sizes range from 1/16” to 1” and 4mm 10mm 11711 .3937 - .3942 10mm x 7/8 x 20 1-1/16 5-5/16
to 25mm. For special applications 12mm 11712 .4724 - .4730 12mm x 1 x 20 1-1/16 5-5/16
contact our customer service. 14mm 11713 .5512 - .5519 14mm x 1 x 20 1-1/16 5-5/16
16mm 11714 .6299 - .6306 16mm x 1 x 20 1-1/16 5-5/16
Why Hassay Savage broaches stand for 18mm 11715 .7087 - .7093 18mm x 1 x 20 1-1/16 5-5/16
precision and top quality: The side relief 20mm 11716 .7874 - .7883 20mm x 1 x 20 1-1/16 5-5/16
eliminates drag in multiple-pass broaching. 22mm 11717 .8661 - .8669 22mm x 1 x 20 1-1/16 5-5/16
24mm 11718 .9449 - .9458 24mm x 1 x 20 1-1/16 5-5/16
Tooth-relief, using Borazontm wheels, improves 25mm 11719 .9843 - .9853 25mm x 1 x 20 1-1/16 5-5/16
surface finish and extends tool life.
*Tolerance considerations are based on preferred metric limits and fits--ANSI B4.2-1978
Precision grinding of the rake face insures con-
sistent performance and free cutting action after
several sharpenings.
An undercut pilot allows easier entry on each
pass.
24
500 & 600 Series Pull Type Broaches
EDP No. EDP No. A Min. Min. Max. B C D E F G No.

500 600 500 600 Nom. Decimal Toler- Hole Length Length + .0000 of Thread
Series Series Series Series Dim. Dim. ance Size Cut** Cut - .0005 ± .0005 Cuts Size
33501 33601 501 601 1/16 .0635 ±.0002 3/8 3/8 1-1/4 .1552 20 .313 .271 7-3/16 .042 1 1/4 - 20
33502 33602 502 602 3/32 .0948 ±.0002 7/16 1/2 1-1/2 .1865 24 .367 .309 8-1/4 .058 1 5/16 - 18
33503 33603 503 603 3/32 .0948 ±.0002 5/8 5/8 2-1/2 .249 33 .491 .433 10 .058 1 3/8 - 16
33504 33604 504 604 1/8 .126 ±.0002 1/2 1/2 1-1/2 .249 30 .438 .364 9 .074 1 3/8 - 16
33505 33605 505 605 1/8 .126 ±.0002 7/8 5/8 2-1/2 .3115 36 .594 .520 10 .074 1 1/2 - 13
33506 33606 506 606 5/32 .1572 ±.0002 19/32 1/2 1-1/2 .249 30 .525 .436 9 .089 1 3/8 - 16
33507 33607 507 607 5/32 .1572 ±.0002 23/32 5/8 2-1/2 .3115 33 .625 .536 10 .089 1 1/2 - 13
33508 33608 508 608 3/16 .1885 ±.0002 11/16 5/8 2-1/2 .374 36 .581 .476 10 .1050 1 1/2 - 13
33509 33609 509 609 3/16 .1885 ±.0002 15/16 11/16 3-1/2 .374 36 .796 .691 10-11/16 .105 1 1/2 - 13
33510 33610 510 610 7/32 .2198 ±.0002 11/16 5/8 2-1/2 .374 33 .557 .437 10 .120 1 1/2 - 13
33511 33611 511 611 11/32 .2198 ±.0002 15/16 11/16 3-1/2 .374 42 .813 .693 11-1/16 .120 1 1/2 - 13
33512 33612 512 612 1/4 .251 ±.0002 11/16 5/8 2-1/2 .374 36 .612 .476 10 .136 1 1/2 - 13
33513 33613 513 613 1/4 .251 ±.0002 1 11/16 4 .499 45 .877 .741 11-13/16 .136 1 5/8 - 11
33514 33614 514 614 1/4 .251 ±.0002 1-7/16 7/8 6 .624 51 1.250 1.114 13-1/2 .136 1 3/4 - 10
33515 33615 515 615 9/32 .2828 ±.0002 7/8 11/16 4 .499 42 .716 .564 11-5/8 .152 1 5/8 - 11
33516 33616 516 616 9/32 .2828 ±.0002 1-1/4 7/8 6 .499 51 1.093 .941 13-1/2 .152 1 5/8 - 11
33517 33617 517 617 5/16 .314 ±.0002 1 11/16 4 .499 45 .908 .741 11-13/16 .167 1 5/8 - 11
33518 33618 518 618 5/16 .314 ±.0002 1-5/16 7/8 6 .499 51 1.158 .991 13-1/2 .167 1 5/8 - 11
33519 33619 519 619 3/8 .3765 ±.0002 1-1/16 11/16 4 .499 45 .938 .739 11-13/16 .199 1 5/8 - 11
33520 33620 520 620 3/8 .3765 ±.0002 1-5/16 7/8 6 .499 54 1.189 .990 13-1/2 .199 1 5/8 - 11
33521 33621 521 621 7/16 .439 ±.0002 1-9/16 11/16 4 .624 48 1.360 1.160 12 .230 1 3/4 - 10
33522 33622 522 622 7/16 .439 ±.0002 2 1 8 .624 48 1.611 1.496 15-5/8 .230 2 3/4 - 10
33523 33623 523 623 1/2 .5015 ±.0002 1-1/2 11/16 4 .624 48 1.312 1.051 12 .261 1 3/4 - 10
33524 33624 524 624 1/2 .5015 ±.0002 1-1/2 1 8 .624 48 1.377 1.246 16-1/2 .261 2 3/4 - 10
33525 33625 525 625 9/16 .5645 ±.0003 1-3/4 11/16 4 .6865 54 1.438 1.146 11-13/16 .292 1 1-8
33526 33626 526 626 9/16 .5645 ±.0003 1-5/8 1 8 .6865 51 1.391 1.245 16 .292 2 1-8
33527 33627 527 627 9/16 .5645 ±.0003 2-1/4 1-1/8 12 .874 60 1.641 1.495 20 .292 2 1-8
33528 33628 528 628 5/8 .627 ±.0003 1-7/8 1-1/16 4 .749 60 1.625 1.301 12-3/16 .324 1 1-8
33529 33629 529 629 5/8 .627 ±.0003 2-1/2 1 8 .874 54 1.657 1.495 16-3/8 .324 2 1-8
33530 33630 530 630 5/8 .627 ±.0003 2-1/4 1-1/8 12 .874 57 1.657 1.495 20 .324 2 1-8
33531 33631 531 631 3/4 .752 ±.0003 1-7/8 11/16 4 .874 60 1.625 1.239 12-3/16 .386 1 1-8
33532 33632 532 632 3/4 .752 ±.0003 2 1 8 .999 60 1.688 1.495 16-3/8 .386 2 1-1/4 - 7
33533 33633 533 633 3/4 .752 ±.0003 2-1/4 1-1/8 12 .999 57 1.688 1.560 20 .386 3 1-1/4 - 7
33534 33634 534 634 7/8 .877 ±.0003 2-1/4 11/16 4 1.124 63 1.875 1.426 12-3/8 .449 1 1-1/4 - 7
33535 33635 535 635 7/8 .877 ±.0003 2-1/4 1 8 1.124 63 1.719 1.494 15-3/4 .449 2 1-1/4 - 7
33536 33636 536 636 7/8 .877 ±.0003 2-1/4 1-1/8 12 1.124 63 1.719 1.569 20 .499 3 1-1/4 - 7
33537 33637 537 637 1 1.002 ±.0003 2-1/4 5/8 2-1/2 1.249 63 1.750 1.239 10-1/2 .511 1 1-1/2 - 6
33538 33638 538 638 1 1.002 ±.0003 2-1/4 7/8 6 1.249 63 1.750 1.494 14-1/4 .511 2 1-1/2 - 6
33539 33639 539 639 1 1.002 ±.0003 2-1/4 1-1/8 12 1.249 60 1.750 1.580 20 .511 3 1-1/2 - 6
*600 Series Designates Notched-Type Shank. **Minimum length of part recommended to prevent part from dropping in between teeth o f broach.
We supply standard pull heads for 500 From the craftmanship of our toolmak- excellent performance from a Hassay
and 600 Series Broaches upon request. ers to the tight standards of our quality Savage HSS broach.
Call us for sizes and delivery. control, you can always be assured of
25

Broaching
The venerable blacksmith will tell you that the 1930s broaching processes could supply the
broaching originated within his craft 3,000 years industry with close-tolerance square holes and
ago. Needing to create internal spaces within the multiple splines for transmission gears. The tech-
pieces he hand-forged, the nology continued to develop spiral spline broach-
blacksmith invented drifts in ing, tooth cutter bars, and broaches manufactured
varieties of configurations to from high-speed steel. By the mid-50’s hydraulic,
punch these shapes. Drifts fully automatic internal and external broaching
were driven by hammer machines were in wide use, making it possible to
through the cherry-red hot reduce the cost of mass producing accurately fin-
metal held on the primitive ished identical parts of all shapes and sizes.
anvil over the pritchel or
hardy hole to form a variety of Today broaching fix-
internal shapes. tures typically incor-
porate mechanical,
The industrial historian, how- hydraulic or pneu-
ever, dates modern broaching matic principles and
back to mid-nineteenth centu- utilize programma-
An automatic broach- ry Germany, where the drifting ble controls and
ing operation using
Hassay Savage one tool incorporated series of uni- automatic clamping
pass broaches. form cutting teeth to remove for continuous cycle
material (much like a wood indexing.
rasp). These first broaches were short heavy Computers increas-
hand-driven push tools. Initially, internal broach- ingly play a critical
ing, such as cutting keyways in pulleys and gears, role in the design
accounted for the bulk of the work done, and as and manufacturing
the power press was developed, applications for set-up of broach tool- Pictured are CNC Push and Strip
Broaches for finish sizing automatic
internal broaching widened. making. The indus- slides after rough milling on CNC
try also asserts its Tsugami Vertical Mills.
Surface broaching evolved more slowly, but by the competitive edge by taking advantage of signifi-
1920’s became critical in meeting the demands of cant technical advances in the fields of grinding,
mass production in the automotive industry. By coolants, lubricants, stock materials, and heat
treatment; which make it possible to produce a
tougher, sharper tool at less cost and with faster
turnaround.
Since 1969, Hassay Savage Company has emerged

as a leader in the development of broaching appli-
cations into may areas of manufacturing where
there is need to produce precise complex shapes
and forms. Forty years later, we are convinced
that by joining state-of-the-art technologies with
the craft of broaching as it has evolved, modern
broaching heads into the twenty-first century as a
competitive alternative to reaming, milling, and
shaping in operations where critical tolerances at
high production speeds in manufacturing identical
parts are required.
26
Broach Manufacturing at
Hassay Savage
We employ strict quality controls for the cutting, milling, heat-treat-
ing, and grinding phases. Production involves some 15 to 20 separate
operations through our machining departments. Each process
involves a skilled toolmaker and a specially fixtured machine to get
the job done efficiently and correctly. Because all of our work is
scheduled by computer, we have a complete and forward vision of all
standard and special orders at each work-station with a scheduled
completion date.
We also apply Statistical Process Control (SPC) within our manu-

facturing process to assure quality broaches. SPC has become a
requirement of many of our large Original Equipment Manufacturer
(OEM) accounts, such as Ford. GM, Chrysler, General Electric,
Caterpillar, and John Deere. Since we conform to documented SPC
procedures to satisfy the quality control requirements of these compa-
nies, we generate a higher standard of manufacturing throughout our
plant for all of our customers.
• In creating a more consistent

product, we have taken our stan-
dard tolerances and made them
closer or tighter within our own
manufacturing to generate a much
more consistent and exacting tool.
• Our skilled toolmakers main-

tain tolerance variability records
on each workstation to scrutinize
any variations or changes that
may occur in the process and to
take immediate corrective action.
• Our quality control lab super-

vises the inspection process per-
formed at each workstation.
• Complete process control

means a better, more consistent
broaching tools and more satisfied
Hassay Savage customers.
The real secret, however, is in our refined broach grinding process....
27

Broach Grinding Process
speed spindles are designed The on-board computer is pro-
specifically for electroplated grammed to produce all of the
CBN wheels. These newer CBN types of broaches manufactured
wheels are made by machining by Hassay Savage. The pro-
the reverse of the tooth configu- grams are used to grind new
ration into a metal core, then broaches and to sharpen older
bonding a layer of CBN abrasive broaches returned to us for
to this machined surface by elec- rebuilding.
troplating. These CBN wheels,
surfaced with BorazonTM, require By joining the latest CNC and
virtually no maintenance; have an CBN grinding in our manufac-
exceptional wheel life; and are turing facility, we offer our cus-
Aggressive cutting action required by tomers new or rebuilt broaches
grinding at high-material rates in creep-feed
mode. held to near-perfect tolerances;
broaches capable of extremely
The most significant technologi- accurate cuts and finishes that
cal advances offered by Hassay consistently meet the most exact-
Savage’s manufacturing and ing specifications, all at reduced
sharpening equipment are in the cost and faster turnaround time.
actual grinding process. First we
cut the basic tooth configuration
in hardened tool steel. Because Broach grinding and sharpening
hardened broach materials are cycle-times have been reduced 30
difficult to grind, Hassay Savage to 50 percent in order to get tools
abandoned the traditional back to you sooner.
Aluminum Oxide wheel in the
CNC grinding with state-of-the-art CBN
early 70s. Switching to CBN wheels means that all broaches-original
wheels at that time nearly dou- and resharpened, get the same exact-
ing treatment at Hassay Savage.
bled our productivity.
Technology has now addressed
the fact that using CBN wheels capable of holding correct tooth
on machinery originally form throughout their long life.
designed for slower spindle
speeds and less rigid tool hold- To compensate for the heat
ers, as required by the AO generated by the high-speed
wheels, failed to utilize the full grinding, the Walter machine
potential of the CBN wheel. uses a straight oil lubricant
applied by intense pressure
Today, we grind our broaches directly to the grinding zone
on Walter Helitronic 4 + 5 Axis which prevents air-borne
grinding machine. These CNC droplets from polluting our work
machines are controlled by an atmosphere while at the same
on-board PentiumTM computer time effectively reducing work-
and its high-power, variable piece friction and distortion.
28
Cost Benefits of a Hassay Savage Broach
It is important to analyze cost savings The traditional strength of the
of any operation when it means more broaching process and its tool is now
money in your company’s pocket. reinforced by innovative technologies
Compared to other operations such as that make it a most profitable manu-
milling, reaming, shaping, and EDM- facturing solution. Built into Hassay
type contour work, broaching over the Savage broaches are the following cost
long run does the job faster and with benefits:
unsurpassed precision.
• CNC/CBN-ground tools
• Extended broach life
• Smoother, more accurate cuts The optical Comparator assures
that all profile grinding of tooth
• Better surface finishes forms and contours meet our
exacting standards.
• More piece parts per hour, per sharpening Flat broaches of up to 4”
(101,6mm) wide and 23.5”
• Less frequent replacement (596,9mm) long; round broaches
up to 4” (101,6mm) in diameter
• Consistent high quality and 65” (1650mm) in length are
• Excellent turnaround manufactured on our CNC
machines.
The Broaching Process Comparison Cost

Time-saving in the Broaching Process Increases Production 3 to 5 Times
29

Rebuilding & Sharpening
In rebuilding a broach, our CNC machine first examines the
entire broach with its touch probe. This procedure accurate-
ly locates the face and gullet of each tooth to measure the
exact spacing, depth and all its angles. The touch probe
compensates for any irregularities stemming from the
broach’s original tooling.
The probing information on each broach is stored in the

CNC machine’s memory and is recalled to guide the grind-
ing wheel through the sharpening process. Consistency is
maintained with the broach’s original grinding, and the cut-
ting job is distributed evenly over the entire tool, sparing the
individual teeth from excessive stress. Only the minimum
amount of metal (.002-.005 inches) is removed to bring all
teeth to exact size while retaining maximum strength on
each tooth.
Hassay Savage’s own CNC-machined broaches do not

require touch probing since their design specifications are
already stored for sharpening maintenance. Not only does
this capability expedite the broach’s rebuilding, but assures Properly sharpened broaches prolong tool life and
keep production costs down. Regular maintenance is
that the regrinding will be absolutely accurate. Our broach built into our service over the life of each Hassay
rebuilding is also accomplished with electroplated Savage broach. Within one to two weeks’ turnaround
we rebuild your broaches to peak working efficiency.
Borazon(tm) CBN grinding wheels for critical accuracy and
high finish.
The Hassay Savage Method of Reconditioning

Broaches require 1. Replace broken teeth by welding where necessary.
sharpening when: 2. Full form grinding of gullet and face of tooth form.
3. Re-grind tooth crests to remove chips and nicks from
• Excessive pressure is necessary teeth.
to run the broach
4. Re-step teeth to proper uniform taper and cutting
• Tearing or poor finish is evident action.
in the part 5. Re-grind existing chipbreakers to give proper chip
• Broach begins drifting during flow.
broaching 6. Relieve tooth crests to provide the proper clearance
for achieving good part finished.
• Chatter occurs during broaching 7. Full quality control inspection to blueprint.
• Cutting section shows signs of 8. Insert tools are re-marked to compensate to original
wear dimension.
30
Tool Material Data
Hassay Savage purchases all of its standard material, M-2 HSS, from one steel mill.
This purchasing strategy assures us of a consisten- We also have available a stock of M-3, M-4, M-42,
cy within batch runs that generates uniform prod- PM-M4, and PM -T15 high speed steels for all spe-
uct throughout our manufacturing process. Our cial broach tooling indicated by material applica-
mill guarantees a quality assurance of 10 to 12 per- tion or difficulty of the broaching process. Each
cent higher carbon content in our M-2 HSS. That high-speed steel lends itself to the special proper-
gives our customers a finished product unsur- ties of wear resistance, toughness, grindability, and
passed in the industry. The comparative proper- relative red hardness, as shown in the accompany-
ties of our material have excellent wear resistance, ing chart (see also chart on page 33).
toughness, and red hardness for the broaching
process in most all types of stock including the
more difficult materials, such as stainless steel.
Comparative Properties for the Selection and Use of High Speed Steels
ANSI Typical Analysis Relative Relative Relative Relative
TYPE Wear Resistance Toughness Grindability Red Hardness
Carbon 0.85
Tungsten 6.15
M-2 Chromium 4.15
Vanadium 1.85
Molybdenum 5.00
Carbon 1.02
Tungsten 6.00
M-31 Chromium 4.00
Vanadium 2.40
Molybdenum 5.00
Carbon 1.32
Tungsten 5.35
M-4 Chromium 4.50
Vanadium 3.85
Molybdenum 4.40
Carbon 1.08
Tungsten 1.50
M-42 Chromium 3.75
Vanadium 1.10
Molybdenum 9.50
Cobalt 8.00
Carbon 1.57
Tungsten 12.25
T-15 Chromium 4.00
Vanadium 4.75
Molybdenum 0.50
Cobalt 5.00
This technical data provides you a starting point from which to work. Our engineers can recommend tool materials
and operating conditions to fit your exact need for process control.
31

Using Broaches
Three major factors affect the broaching process. Recognition and control of these factors permits a
Hassay Savage Broach user to productively realize the accuracy and economy already engineered into
our product.
Material to Be Broached Tool Alignment

Hardness and composition of the metal determines Poor alignment will cause tool breakage and drift-
how effectively a part can be broached. Any mate- ing which produces a part cut outside accepted
rial harder than Rockwell 35 (R35) should not be tolerances. To insure proper alignment:
attempted. Brass and bronze may require some
slight alteration of tooth crest to prevent drift. 1. At least two teeth of the broach should be
engaged at all times.
Telltale Signs That Mean Resharpening
2. Bushings should extend below (or beyond)
workpiece to provide appropriate support for the
broach.
3. In push broaching, the tool should be centered

below the ram so that the ram thrust forces will
drive the broach directly through the bushing to
avoid drift.
4. An appropriately dimensioned pilot hole

should be accurately drilled as a start for the
broach tool.
Troubleshooting Broaches
Poor Finish: Material too soft; alignment of 5. Alignment will be adversely affected even
broach incorrect; coolant incorrect or improperly when all of the above are correct if the broach tool
applied; dull or poorly sharpened broach. has become dulled though long use or incorrectly
Chatter Marks: Broach too sharp; coolant incor- used in materials that were initially too hard. Dull
rect or improperly supplied; lower broach speed broaches will produce cuts with incorrect toler-
required; dull or poorly sharpened broach; tooth ances, unacceptable finishes, and will drift out of
space incorrect. their intended alignment.
Broach Drifting: Support and alignment of
broach incorrect; material too soft; dull or poorly
Hassay Savage broaches are provided with a full
sharpened broach.
tang and pilot to ensure proper alignment and a
Excessive Edge Wear: Abrasive material; coolant rear guiding section.
incorrect or improperly applied; broaching speed
incorrect; incorrect type of HSS.
Chipping: Too little or wrong type of lubricant;
tooth spacing may be incorrect for the work-
piece’s material composition; tool speed too rapid
for effective chip removal; chip load too high.
32
Lubrication
Any cutting process involves friction. Friction
causes heat, distortion and vibration; all of Lubricant Guide
which adversely affect the broach cut.
Lubrication of the tool helps reduce friction Steel: A good grade of cutting oil or water
and, at the same time, assists in chip removal. soluble coolant. Cutting oil sprayed on
This guide and the accompanying chart provide the broach teeth reduces friction on
general recommendations for lubricants. Our mild steel. Hard steels, especially those
engineers can suggest certain additives for containing nickel, may require a chloine
enhanced lubrication. It is important to remem- additive to a sulfur based cutting oil.
ber that lubrication can make or break a job.
Brass: Broach brass dry or with water soluble
lubricant.
Copper and
Bronze: Oil or water soluble oil is recommended.
Cast Iron: Broach without lubricants. Use oil to

lubricate between broach and shim or
bushing.
Aluminum: Special lubricants required, depending

on the nature of the aluminum. Harder
varieties may be treated as soft steel. In
general, the alloy manufacturer’s
recommendations for low-speed
machining operations should be
Straight oil lubricant with additive is applied to reduce followed.
friction and heat during the broaching operation.
High Grade to Low Grade Materials That Are Broachable

Broach Rake Face Max. per Speed
Material Tool Grade Angle Tooth Chip Load PPM* Coolant
Monel Alloy PM T-15, PM M4 18° 0.002 12 Oil w/25% Sulfur Add.
Nickel Alloy PM T-15, PM M4 15° 0.002 10 Oil w/25% Sulfur Add.
Beta Alloy PM T-15, PM M4 18° 0.002 10 Oil w/25% Sulfur Add.
Titanium Alpha-Beta Alloy PM T-15, PM M4 14°-18° 0.003 8 Oil w/25% Sulfur Add.
Malleable Cast Iron PM T-15, PM M4 6°-8° 0.002 10 Oil--No Additive
Stainless Steel PM T-15, PM M4 18°-20° 0.002 8 Oil w/Sulfur Additive
Stainless Steel Cast PM T-15, PM M4 18°-20° 0.002 20 Oil w/Sulfur Additive
Stainless Steel Wrought PM T-15, PM M4 18°-20° 0.003 20 Oil w/Sulfur Additive
Armor & Aircraft Plate PM T-15, PM M4 12°-15° 0.002 15 Oil w/Sulfur Additive
Tool Steel PM T-15, PM M4 12°-15° 0.002 10 Oil--No Additive
High Strength Steel M-2 15°-18° 0.003 20 Oil Base Water Soluble
Free Machining Steel M-2 12°-15° 0.004 30 Oil Base Water Soluble
Medium Carbon Steel M-2 12°-15° 0.003 25 Oil Base Water Soluble
Low Carbon Steel M-2 12°-15° 0.004 30 Oil Base Water Soluble
Aluminum Alloy T-5, T-6 M-2 (T-5)6°-10° (T-6)15°-18° 0.006 40 Oil Base Water Soluble
Magnesium Alloy M-2 15°-18° 0.006 40 Oil Base Water Soluble
Copper Alloy M-2 12°-15° 0.005 25 Oil Base Water Soluble
Brass M-2 0°-3° 0.006 30 Oil Base Water Soluble
Bronze M-2 0°-3° 0.006 30 None or Water
Plastic M-2 10°-12° 0.010 30 None or Water
Wax M-2 0°-3° 0.08 30 None or Water
33

Special Broaches
Selected Broaching Research and Development
Applications Integration of design and manufacturing processes
at the prototype stage is important for successful
The following list will give you an idea of the kind precuts. Hassay Savage can save you time and
of first-rate special broaching that distinguishes our money when our engineers are involve from the
company world-wide. Selected applications are: outset. We routinely assist the following industries:
• Metering Valve: 0.524” x 1.706” rectangle 20”
push broach: broached at Hassay Savage with Automotive Aircraft Communication Systems
100% inspection for just-in-time shipments to Electronics Military Farm and Constructions
OEM; job lot of 25,000 pieces. Aerospace Plastics Ammunitions
• Control Vent Airframe: 40 slots in rectangle Broaching is expanding into areas opened by state-
chamber; 1.625” x 6,000”; broach was pull-type on of-the-art technology. Once limited to the machin-
horizontal machine; accuracy of 0.001 required ing of ferrous metals, broaching now is also applica-
throughout reference of all points; job lot of 100 units. ble to non-ferrous metals and non-metallic materi-
• Printing Guide Lever: 19mm x 1,6mm rectangle als such as plastics, ceramics, and wood products.
610mm pull broach; bronze workpiece; limited Broaching is also combining with other processes to
production. create machining centers and flexible manufactur-
• Wave Guide: 1.345” x 2.848” 36” pull broach; job ing systems which utilize quick change workpiece
lot of 500 pieces, on continuous basis. tooling and broach tool changing systems. At
• Control Pin: flats and radius slot; insert type slab Hassay Savage we are committed to supporting the
broaches and radius slot broaching on vertical exploration of broaching’s full potential as it
machine; high volume run. unfolds. We subscribe to the research efforts of
• Control Valve: Double D 14,09mm x 21,69mm Ohio University’s Broaching Research Laboratory
pull broach; highly specialized DD hole in titani- and with this affiliation we are working on:
um material; small volume, annual run.
• Expert systems for the automation of the broach
• Pliers: Set of three surface broaches to broach
design process.
teeth of pliers; open clearance and cut-off section;
• Integrated system for the near-net shape (pre-
high volume run.
forming) manufacture of broaching tools.
• Collets: 6 slots; 0.093” width; slotting broaches for
• A knowledge-based system for yielding maxi-
cutting collet slots on vertical broach; high volume
mum allowable cutting force during broaching by
with a great variety of sizes using same broaches.
creating exacting tooth geometry.
• Ratchet Wrench: Elliptical set of holes for mecha[
• Computer-aided process of down-loading
nism of ratchet; limited volume run.
machining programs to workstations by the actu-
• Internal Spline Gear: 22-tooth 36” spline pull
al routing process.
broach; 24/48 diametral pitch; 20° pressure angle;
• Procedures that reduce the cost of designing, man-
2 million pieces per year.
ufacturing, and rebuilding broaches.
• Surgical Scissors: 4” wide, 16” long surface
broach; stainless steel workpiece; continuous The broach is an unsurpassed unique tool that gener-
medium volume run. ates finish shapes in one pass. Broaching has a distinct
advantage over other metal cutting operations because
of its exacting precision, superb finish, and faster pro-
duction rates (as much as 25 times higher). Wherever
broaches can be utilized, quality and productivity
improve significantly. Using the Hassay Savage sys-
tem gives you the best assurance the industry has to
offer.
34
If you require a special broaching operation, let Hassay Savage create a complete system of broaching
that provides an expert engineering solution to your application. When our tooling is being used in
your facility, we give you 100 percent technical service and commitment to assure you the built-in prof-
itability of a Hassay Savage broaching tool.
Special Broaches
35

Ordering
Standard broaches may be All of Hassay Savage tools are subject to UPS weight limita-
ordered through your nearest available with titanium nitride tions. Other specified air and
Hassay Savage industrial dis- coating as a standard product. surface freight companies are
tributor for off-the-shelf delivery. Please contact our customer available at your request for
When ordering from our stan- service for details. expedient and express service.
dard stock, speciify the EDP Shipments are FOB Turners
number with type and size as We guarantee immediate ship- Falls, MA, unless otherwise
listed in the appropriate table ment by reliable door-to-door stated.
found on page 5 through 25 of United Parcel Service to any
this catalog. point in the Continental USA,
Broaching Machinery Available Through Hassay Savage

We can supply the following American-made machinery:
Contact our customer service for pricing and technical assistance.
To the Distributor
Hassay Savage broaches offer tomers. Ask our customers Hassay Savage offers:
your customers the benefits of about our service record for qual- • Unsurpassed high-quality
advanced design and the latest ity and integrity. We are proud of products made by experienced
market technology in manufac- our worldwide reputation. toolmakers
turing. Our strict quality controls Under ISA (Industrial Supply Association) we • Consistent product mix
and skilled group of toolmakers are organized by their standard numbering
• Excellent profit structure
system. Hassay Savage Co. Manufacture’ s
insure that Hassay Savage Code -- 615948 (Uniform Code Council). • Timely service
broaches cut more precisely, last • Pride in what we do
longer, and wear better to make • Experienced craftsmanship
money for you and your cus-
36
Hassay Savage Company
distributed by :
O
Newman Tools Inc. M
Tel 1-800-465-1384 Fax 1-800-605-2442
Tel 613-836-6776 Fax 613-836-9070
www.newmantools.com
Oct 2010

Broach Rotary Hassay NT

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Broach Rotary Hassay NT

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Hassay Savage Company

Precision • Performance • Profitability

Newman Tools Inc.

We can show you how broaching can be a superior, cost-

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

Surface broaching is especially effective

Internal broaching tools include the Double D pull

Internal broaching solves scores of

Our engineers can integrate the design and manu-

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

Rake and relief

For special widths and depths, cus-

All of Hassay Savage tools are available with tita-

Standard Set C-1 Collared EDP No. 15318

Standard Set C-1A Collared EDP No. 15319

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

Metric Set #30 Hardwood EDP No. 15230

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

Dura Case Broach Kits

DIN Standard For Keyways

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Standard Set 3-DA Hardwood EDP No. 15124

Heavy Duty Set 4-E Hardwood EDP No. 15012

Heavy Duty Set 5 Hardwood EDP No. 15026

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

One Pass Keyway Broaches

One Pass Metric Keyway Broaches to ISO H9 Tolerance

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

Square Rotary/Punch Broaches

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

FOR BROACHES WITH 1/2” - .500 SHANK

You can successfully broach these shapes & others

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

The process of setting up and

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

5. Turn the handwheel on the fix-

We have been insturmental in Swiss Style Broach

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

Swiss Style Holders

2160 Series Holders

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

Standard Metric Square Broaches

Standard Full Square Push

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

EDP No. EDP No. A Min. Min. Max. B C D E F G No.

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

Since 1969, Hassay Savage Company has emerged

We also apply Statistical Process Control (SPC) within our manu-

• In creating a more consistent

• Our skilled toolmakers main-

• Our quality control lab super-

• Complete process control

The real secret, however, is in our refined broach grinding process....

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

The Broaching Process Comparison Cost

www.newmantools.com tel 1-800-465-1384 fax 1-800-605-2442

The probing information on each broach is stored in the