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Round Broaches: A Comprehensive Guide for Industrial Machining

Round broaches are unique broaching tools designed to cut circular profiles, holes, and grooves in shafts, bearings, and components where standard keyway or spline broaches are not suitable. Their precision and ability to produce smooth internal surfaces make them a preferred choice in industries demanding high accuracy.

At Amit Broaches, we manufacture round broaches for automotive, aerospace, defense, and heavy machinery industries, providing tools with long life, high accuracy, and exceptional surface finish.

Round Broaches

What Are Round Broaches?

A round broach is a tapered cutting tool designed to enlarge, finish, or ream a circular hole to a precise diameter. Unlike flat or keyway broaches, round broaches create uniform circular cuts. They can be:

  • Push broaches (pushed through the workpiece)

  • Pull broaches (pulled through for higher accuracy)

Advantages of Round Broaching

  • Accurate diameter control

  • Smooth surface finish

  • Uniform circular profile

  • Reduced machining time

  • Minimal operator skill needed

Types of Round Broaches

Amit Broaches offers a variety of round broaches depending on the application:

1. Circular Hole Broaches

For enlarging or finishing existing holes with high precision.

2. Step Round Broaches

Cut multiple diameters in a single pass, saving time in machining operations.

3. Reaming Round Broaches

For finishing hard-to-machine metals with smooth surface finish.

4. Multi-step Circular Broaches

Specially designed for progressive diameter cuts or bore finishing.

5. Custom Round Broaches

Engineered according to OEM drawings, including unusual profiles, counterbores, and complex diameters.

Types of Spline Broaches Manufactured at Amit Broaches

1. Push Type Spline Broaches

For cutting splines in softer metals or when machining shorter bores.

2. Pull Type Spline Broaches

Used in heavy-duty industries and for deeper spline machining.

3. Round Broach Style Splines

For specific tools and small internal diameters.

4. Form Broaches

For custom or complex spline patterns.

5. Progressive Spline Broaches

With multiple modules/stages for extremely tight tolerances.

Each broach is engineered for long life and consistency.

Materials Used in Round Broaches

The longevity and cutting precision of round broaches depend heavily on the material:

1. High-Speed Steel (HSS)

  • Most widely used

  • Provides excellent wear resistance and durability

2. Powder Metallurgy Steel

  • Long-lasting and ideal for high-volume production

3. Carbide-Tipped Broaches

  • For cutting hardened materials or high-precision aerospace components

4. Coatings

  • TiN, TiCN, TiAlN coatings to reduce wear and heat

  • Enhance tool life and performance

Manufacturing Process of Round Broaches

At Amit Broaches, each round broach undergoes a multi-stage manufacturing process:

  1. Material Selection
    Certified premium HSS or PM steel is chosen.

  2. CNC Machining
    To create tapered teeth and precise cutting geometry.

  3. Heat Treatment
    For hardness, wear resistance, and dimensional stability.

  4. Grinding & Finishing
    Ensures smooth cutting edges and precise diameter.

  5. Optional Coating
    Enhances tool life, reduces friction, and improves heat resistance.

  6. Quality Inspection
    Each broach is checked for diameter accuracy, taper consistency, surface finish, and tooth profile.

Applications of Round Broaches

Round broaches are essential across multiple industries:

1. Automotive

  • Engine bores

  • Transmission shafts

  • Bearing housings

2. Aerospace

  • Precision landing gear components

  • Engine parts

  • Circular slots in high-tolerance components

3. Heavy Machinery

  • Hydraulic cylinder bores

  • Pump housings

  • Gear bores

4. Industrial Equipment

  • Bearings, bushings, and rollers

  • Circular internal features in machine parts

5. Defense

  • High-precision circular bores in weapons and vehicles

Advantages of Using Round Broaches

Round broaching offers unique advantages over other machining processes like drilling or milling:

  • Single-pass cutting for precision
  • Consistent diameter and circularity
  • High-speed production in large quantities
  • Smooth surface finish reduces post-processing
  • Durable and long-lasting tools
  • Versatile for multiple materials, including hardened steels

How to Select the Right Round Broach

Consider the following before purchasing:

  1. Bore Diameter – must match broach size

  2. Workpiece Material – determines HSS, PM, or carbide

  3. Bore Depth – affects push vs pull broach selection

  4. Production Volume – high-volume requires coated or PM steel broaches

  5. Finish Requirements – smooth or semi-finished bore

Our engineering team helps customers select the ideal broach for their exact needs.

Maintenance and Re-sharpening

Proper care ensures long life and repeatable accuracy:

  • Regularly inspect teeth for wear

  • Re-sharpen when cutting efficiency drops

  • Use coolant during machining to reduce heat

  • Store broaches in protective cases

  • Avoid overloading during broaching

Amit Broaches also provides professional re-sharpening and reconditioning services to extend the life of your round broaches.

Why Choose Amit Broaches for Round Broaches?

    • ISO-certified manufacturing

    • CNC and precision grinding capabilities

    • Premium HSS, PM steel, and carbide broaches

    • Custom designs as per OEM drawings

    • 100% inspection for accuracy and surface finish

    • Competitive pricing with fast delivery

    • Reliable technical support

    Industries across India trust Amit Broaches for high-precision, durable, and accurate round broaches.

Conclusion

Round broaches are critical tools for creating precise circular internal profiles in automotive, aerospace, defense, and industrial machinery components. They offer unmatched accuracy, efficiency, and consistency over conventional drilling or milling.

At Amit Broaches, we manufacture high-quality round broaches tailored to customer requirements, ensuring superior performance, long life, and precision machining results.

Contact Us

Looking for premium Round Broaches?

Call: +91-9814229208
Email: info@amitbroaches.in
Website: www.amitbroaches.in
Location: Punjab, India