Thread: Hex broaching in thick aluminum stock
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Unread 19-02-2016, 14:45
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AKA: Alan Gilgenbach
FRC #2062 (C.O.R.E. - Community of Robotics Engineers)
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Re: Hex broaching in thick aluminum stock
Quote:
Originally Posted by Joey Milia View Post
While some sort of insert would probably be better design wise I'm just going to comment on the broaching.

I've heard that it's recommend your broaching length doesn't exceed 2x your broaching diameter. So for 1/2 hex 1" would be the edge of that recommended range. However, 192 has done up to 1.5" long 1/2 hex in aluminum belt pulleys for our drivetrain without problems. This is done with cutting fluid on a hydraulic press. If you don't have access to a hydraulic press this may not be possible with an arbor press. There will obviously be higher loads involved as you'll have more teeth engaged at once so be extra careful the broach is kept straight. 6061 is probably the safer bet, softer should be easier to cut.
Joey,

Are you making the trip to Wisconsin this year? That's our home regional. Let me know if you guys need any help finding your way around etc. We'd be glad to lend a hand.
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