+91-9814229208
info@amitbroaches.in
In modern machining and manufacturing, keyways play a crucial role in torque transmission for shafts, pulleys, gears, and coupling systems. To achieve these precision keyway slots, industries rely on Keyway Broaches a tool engineered for accuracy, stability, and durability.
At Amit Broaches, we specialize in high-performance keyway broaches used across automotive, aerospace, defense, machinery manufacturing, and heavy engineering industries.
This in-depth guide covers everything you need to know from types and materials to applications, advantages, and why keyway broaches remain an essential tool for internal machining.
A keyway broach is a long, tapered cutting tool used to cut internal keyway slots inside bores. It is designed to remove material in a single pass, using multiple progressively larger teeth to produce a clean, accurate slot.
A typical keyway broach system consists of:
Broach Tool (the cutting tool)
Shim or Guide
Broaching Machine (vertical or horizontal)
How It Works
The broach is pushed or pulled through a pre-drilled bore. Each tooth removes a slightly larger amount of material until the final slot size is achieved.
The result is:
- Perfect slot finish
- Accurate depth
- Consistent width
- Zero deflection
This makes broaching one of the fastest and most reliable machining processes for keyway cutting.
Types of Keyway Broaches
Amit Broaches manufactures all major types of keyway broaches, customized for specific applications.
1. Standard Keyway Broaches
Ideal for general-purpose keyway machining in gears, pulleys, couplings, and industrial components. Available in fixed metric and imperial sizes.
2. Metric Keyway Broaches
Used widely across European, Indian, and international standard machinery.
3. Inch Keyway Broaches
Manufactured according to ANSI/AISI standards.
4. Internal Keyway Broaches
For cutting inside bores of shafts, gears, or sleeves.
5. Special / Custom Keyway Broaches
Designed as per drawing or application — these are ideal for OEMs who require unique dimensions, fits, or tolerances.
Materials Used in Keyway Broaches
A broach’s strength and life depend primarily on its material. We manufacture using premium-grade steels:
1. High-Speed Steel (HSS) – M2, M35, M42
Most popular material for its:
Hardness
Wear resistance
Ability to maintain sharpness under heat
2. Powder Metallurgy Steel (PM Steel)
Used for high-strength broaches that require extreme life in high-volume production.
3. Carbide-Tipped Broaches
For cutting hardened materials and high-precision applications.
4. Coatings (Optional)
TiN
TiCN
TiAlN
Coating improves life, reduces friction, and increases tool stability.
Manufacturing Process of Keyway Broaches at Amit Broaches
Amit Broaches follows a rigorous, quality-controlled manufacturing process, ensuring each tool meets international accuracy standards.
1. Raw Material Selection
Only certified, tested HSS or PM steel is chosen.
2. CNC Machining & Grinding
To achieve accurate tooth geometry and taper.
3. Heat Treatment
Ensuring hardness and wear resistance.
4. Final Grinding
Achieving a precision finish and perfect cutting profile.
5. Coating (Optional)
Based on customer needs or material specifications.
6. Quality Inspection
Each broach is tested for:
Tooth profile
Straightness
Taper accuracy
Hardness
Surface finish
This ensures 100% performance in real-world applications.
Applications of Keyway Broaches
Keyway broaches are used across several industries:
1. Automotive Manufacturing
Gear components
Shafts
Steering arms
Transmission parts
2. Heavy Machinery
Pulleys
Couplings
Industrial motors
3. Aerospace
Where accuracy and repeatability are critical.
4. Tool & Die Making
Broaching ensures perfect fit for tools and mandrels.
5. Defence Sector
Used for precision weapon parts, locking systems, etc.
Advantages of Keyway Broaching
Broaching is preferred over milling and EDM for keyway cutting due to:
- Single-pass machining extremely fast
- Highly accurate slot dimension
- Superior surface finish
- Less operator skill required
- Higher productivity in mass production
- Suitable for both soft and hardened materials
This is why manufacturers across industries classify broaching as the most efficient method for internal keyways.
How to Select the Right Keyway Broach
Choosing the right broach depends on:
- Material being machined
(Soft steels vs hardened materials require different broaches)
- Slot width & depth
Broach size depends purely on slot requirements.
- Bore diameter
The tool must match the guide size.
- Production volume
High-volume manufacturing may require coated or PM-steel broaches.
- Machine type
Vertical, horizontal, or special broaching machines influence tool selection.
At Amit Broaches, our engineering team helps customers choose the best match for their production needs.
Maintenance & Re-sharpening of Keyway Broaches
Proper maintenance increases tool life by 60–70%.
- Regular inspection of teeth
- Immediate re-sharpening when finish reduces
- Coolant lubrication during machining
- Proper storage
- Using correct guides & shims
We also provide professional re-sharpening and reconditioning services for all types of broaches.
Why Choose Amit Broaches for Keyway Broaches?
Amit Broaches is known for:
- ISO-standard manufacturing
- CNC + precision grinding machines
- 100% inspection before dispatch
- Competitive pricing
- Custom-built broaches
- Quick delivery
- Expert support for OEMs and industries
- Our broaches are trusted by industries across India for their accuracy, durability, and performance.
Conclusion
Keyway broaches remain one of the most essential tools in precision machining. Whether you manufacture automotive parts, gears, pulleys, or industrial machine components, the right broach ensures perfect alignment, accuracy, and strength of the final product.
At Amit Broaches, we deliver high-quality keyway broaches made from premium HSS/PM steel, engineered for long life and exceptional performance. Our tools are designed to meet the strictest industry standards and the evolving needs of modern manufacturing.
Looking for premium-quality Keyway Broaches or customized broaching tools?
Call: +91-9814229208
Email: info@amitbroaches.in
Website: www.amitbroaches.in
Location: Punjab, India