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Broaching a Keyway: A Steel Pulley Turned, Bored and Keyed
A broach is a long cutter whose teeth get a little taller one after another, so one push through a hole cuts a finished shape. Broaching began in the 1850s for exactly this job: cutting the keyway in a pulley or gear so it can be locked to its shaft.
Intermediate
Half a day
Instructions
1
1
Watch: what is broaching?
Watch: what is broaching?
Broaching types, the machine and the broach's teeth, in a short course preview.
2
2
Turn the pulley
Turn the pulley
Saw a slice of round bar, face both sides and turn the rim to size on the lathe.
Materials for this step:
Mild Steel Round Bar1 pieceTools needed:
Hacksaw
Metal Lathe
Cutting Oil
Vernier Caliper3
3
Bore it for the shaft
Bore it for the shaft
Drill and bore the centre to fit the shaft, and break the sharp edges.
Tools needed:
Metal Lathe
Boring BarVernier Caliper
File Set4
4
Set up the horn and broach
Set up the horn and broach
Slide the horn (the slotted bushing) into the bore and set the pulley flat on the arbor press table. Drop the keyway broach into the horn's slot, teeth facing the bore wall, small end first.
Tools needed:
Broach Horn
Keyway Broach
Arbor Press5
5
Push it through in one stroke
Push it through in one stroke
Oil the broach and press it straight through in one steady stroke. Each tooth cuts a little deeper than the last, so the keyway comes out finished.
Tools needed:
Arbor PressKeyway BroachCutting Oil6
6
Clean and check
Clean and check
Take out the broach and horn, clear the chips and check the key slides in snugly.
Tools needed:
Vernier CaliperFile SetMaterials
1- 1 piecePlaceholder
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