Spare Parts #13 - Making A Square Broach
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- Опубліковано 3 жов 2024
- Making A Square Broach, by Clickspring.
It's not necessarily a common event, but when you need to make a square hole, it can be difficult to get a precise result. One of the best methods to achieve a professional cut is to use a custom made broach, so in this video I go through the process of making one from scratch.
Free Plans: www.clickspring...
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A very special thank you to patron Dan Keen.
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Cameras used in this video:
Panasonic GH5 - amzn.to/2rEzhh2
Panasonic X920 - amzn.to/2wzxxdT
Tools & Shop Products:
"Solidworks 2013 Bible": amzn.to/2FObS1D
"Hardening, Tempering and Heat Treatment (Workshop Practice Series)" - amzn.to/2KbZo6l
Sherline Lathe: amzn.to/2pnXM19
Sherline WW collets: amzn.to/2FYZ7F8
Heavy Duty Arbor Press: amzn.to/2G4gog7
Generic Dial Indicator 0.001": amzn.to/2FOFTyF
Norton 1-by-2-by-8-Inch Fine/Coarse India Combination Oilstone, Red: amzn.to/2tTEPb0
Kaowool 24" X 12" X 1" 2400 F Ceramic Fiber Insulation: amzn.to/2pfsM3d
Abbreviated Transcript:
00:06 No matter what your style of metal working project might be, every now and then there's a need to form a precise square hole.
00:21 A pilot hole locates the exact position of the desired square, and then the broach is forced through the workpiece.
00:53 And that's because, all of the teeth prior to the last tooth collectively prepare the opening for the final tooth to set the dimension, so within reason, we can tolerate some small errors in those teeth, providing that the very last one is correct.
01:26 Its much too long and slender to be turned between centers, so I'll need to form the features by incrementally extending the work from a 4 jaw chuck. And the other key feature is the pilot diameter, which must be centered on the square, so I'm taking care to center the raw stock prior to forming that cylindrical shape.
01:48 I have the work reasonably well centered to begin with, so that when I position the dial indicator, the error that I see for each jaw is quite small I then use 2 chuck keys in opposition to each other, to move the work, so that the dial reads directly between the original 2 readings for both jaws.
02:13 Once its close, I move the zero reference to that point, so that becomes my target when I start to center the other two jaws. Once the work gets close to being centered, the errors start to sit nicely either side of that zero reference, and it gets easier to pull it into position.
02:53 But even doing this quickly, you can see that it will take a fair amount of time to do this for every cut, so there's a strong incentive to bypass this centering process if we can. For now though, the work is centered, so I can make a start on cutting that pilot diameter.
03:39 Next I'm using the first groove position to register the tool after extending the work, and then I'm using the hand wheels to advance the tool the required amount to form the next groove. Now inevitably I will have introduced a small eccentricity to each of these cuts, and the teeth won't be precisely spaced either. But as I mentioned before, they don't really need to be.
04:14 Providing I don't introduce any gross errors, It's close enough for the final result, and by accepting a small error, I can move through this part of the process very quickly.
05:14 The total amount of metal to be removed, is determined by the difference between the pilot diameter and the diameter of the circle that just encloses the final square. That metal removal must now be shared across all of the teeth, so it determines how much I feed out before cutting each tooth, and that in turn ends up determining the broach depth of cut.
05:32 The diameter difference also gives an indication of how many teeth are required to keep the chip load manageable.
06:15 At this point all of the features of the broach have been formed, so it can now be quench hardened, and on this occasion I'm using the tray that I recently made for the current clock project.
07:07 In an industrial setting a broach is far more likely to be pulled through the work rather than pushed like this, and there's a real risk of fracture using an arbor press in this way, so be sure to take it carefully.
07:19 Make sure the broach is perfectly vertical before you push it through, and as always have your eye protection on. But even with all of the compromises, its still a great way to use home shop tools to quickly shape a precise square hole.
Making A Square Broach, by Clickspring.
as a retired machinist/welder/fabricator/hobby blacksmith, I love watching your video. takes me back to the productive days that I miss.
Terrific to have you watching mate :)
Of all the videos I watch - your dominate in: Interest, Delivery, Production. You have it nailed.
+Daniel Wahl Thank you very much Daniel, I very much appreciate your support :)
We had to learn to broach a square hole to make a hacksaw in our first semester of school. We were the first class to get a broach while all the other classes had to use a file. The 10mm broach we used had a nice pricetag of around $750. I was quick to make my tasks on the lathe and asked my teacher if i could make my own broach for fun, but he said it is almost impossible to make one...
Gues i'm gonna do the almost impossible on my own lathe soon :D
These videos are never boring. Well sometimes they are but boring in the right way.
Clickspring, the only channel I always click like before even watching the video, a guaranteed quality and informative production. Always a pleasure to watch you work.
+Jim Brockie Terrific to hear that Jim, very much appreciate your support :)
" a small eccentricity"? Dude... there are robots that are less precise than you! Awesome skills. Subbed on the basis that a shop made square broach is an awesome McGyver tool!
Lol, he's very modest, ain't he 😄
why that profile pic?
@@imapigeonyoupeasant1489 why yours?
@@Alucard-gt1zf Mate, that was more than 2 years ago. His profile picture most likely changed since then. And since you asked, mine is of a pigeon because they're the supreme species and you're a peasant.
The toolmaking videos are just as interesting as the clockmaking videos.
+Cesotoseot Very pleased to hear that, these take just as much effort to make :)
+Clickspring I enjoy the toolmaking more than the clock making because I'll never make a clock but I might use one of these tools one day.
I watch the clock videos still because they are very well produced and just a pleasure to watch.
+Cesotoseot yeah i like that part a lot as well, his clockmaking is absolutely gorgeous but the quick and effective nature of the tool making videos has a certain charm.
That has to be the cleanest machine and workplace I have ever seen.
depenthene I know right
depenthene I too try to keep my workshop neat and tidy, it is a necessary evil when welding (my shop tool weapon of choice). It is good practice to methodically keep your work area clean and tidy. However, even though I love this guy and the work he produces, yeah.....His cleaning schedule must be OCD to the max! I bet his missis loves it when he's at home, cleaning all day lol
I have no intention on ever making a broach or even have the need for one and I still watched this all the way through. Amazing production. Everything about this video was in perfect detail it seemed.
Who can actually dislike clicksprings videos? This content is top notch and fun to watch
Who new such a broach could be made like this? So simple, yet such sophistication. Thank you.
+Roy Lucas Cheers Roy, great to have you watching :)
I love that every little piece you make feels like its own project. When I make things, I always look at the project as a whole. This video showed me that even one small piece of that project should be a project in itself and care should be taken for every little piece. Your work is always impressive. Thanks for the video.
+Ty Mansfield Great to have you watching Ty :)
Good point 👍
Tool maker,Clock maker,Film maker, Narrator. Wow, thanks Chris keep 'em coming!
I have never been as relaxed and calm as I am watching these videos. Great stuff, great stuff.
+Napsu Great to have you watching :)
I have no idea why I needed this information but I don't feel disappointed at all. Now I know how to make a square hole.
There's something very satisfying about watching the broach work through that sheet in the final shots and making that perfectly shaped hole; thanks for the video!
It's not just Chris' videography or the Hugh Jackman accent. The CAD overlays really add a lot to the educational value of the content. As always, well done Chris!
+Thomas Utley Cheers Tom, loving the progress with the SB :)
I shivered when you showed the used broach. Too many flashbacks of metal splinters cleaning them.
Never mind the tool porn or the actual results (both of which are just brilliant), your explanation of the path to the result always makes watching your channel worthwhile, Chris. Thank you. Greetings from sunny Adelaide!
+greaser5691 Cheers Greaser, great to have you watching, right back at you from humid Cairns :)
I have no idea why I watch these videos, and I don't think I'll ever make use of the information you provide me with, buuut!! I just love watching your videos. I just do!
+Jose GomezFranco Terrific to hear that! Keep watching :)
This continues to be a highly professional and fascinating series. You make these intricate processes seem effortless. I can't wait to see your clock project finished.
+Adam Ward Me too! New clock episode in the works, should be out in a little over a week, thanks for watching Adam
Hoi Chris, as grandfather age 68 i´m helping grandson age 10 who discoverd thechnic. For his to toy he needs a square hole. This video will help to explane him. Next step we will do it together in my hobby garage. Regards from the Netherlands
I like commercially available tooling but there is just something more satisfying in making and using your own. Great video.
+comictrio So true, and a real money saver too, thanks for watching :)
Clickspring, you have to be an exceptional man of many talents, your talents impress me as I think I could be, being able to be as precise as you are working on the small scale as you do. If I could get close to your knowledge and ability I'd be a happy camper..... Thanks for sharing your many videos.....
That is one geometrically pleasing object you have there Chris. Thanks again as always, and take care!
+Harlequin314159 Cheers mate :)
When tools are invented to create tools invented to create tools. Fascinating, thank you!
I must confess, when I watch your videos I feel so calm! Just watching this things getting incredibly done it's like therapy. Your videos are amazing. I don't know if it's only me lol.
+Felipe Wosniak Very pleased you're enjoying the videos Felipe :)
Chris, I've been following you for months. Every single time I pull up UA-cam and you have a new video pop up, it's the first thing I click on. I can honestly say I've never been disappointed with any of your videos (and I've watched them all). Keep up the good work, looking forward to the finished project!
+JaredC87 Cheers Jared, terrific to have your support :)
That tiny little lathe is adorable. Looks like a great one to start with in case you don't know if you'll like the hobby, though.
yes I agree, a perfect starting point, thanks for watching mate :)
Hooray for a new video! It's been a little while and I was starting to go through withdrawals. I can't get enough of this channel.
What an awesome job. The quality of the footage is equally impressive!
I've been watching a lot of videos about square holes on youtube and this is the best way ! best method！！！！！！！
6500 views in 1 hour with 775 likes and 1 dislike. Son of a -------- who would have thought clock making could draw such a crowd? Clock Making Porn????? For the discerning Machining Porn Viewer.
Just stirring Chris, you know I know how good your videos are and deserve viewing multiple times.
Production quality is right up there with Frank Howarth. Keep 'me coming, Chris!
I thoroughly enjoy the lovely problems solved by home-shop craftsmen.
Your vids are a perfect form of education, meditation and fascination! Thanks for putting out such great work.
+Dustin Bean 100% tool-skill, photography, lighting, editing, 3D overlays, script, accent/style
Liked the presentation. A practical, step to next step, approach.
I just tried your method for a 4 mm sq hole. W1 steel broach into a brass collar for cuckoo clock minute hand. Worked great! Small amount of drag out the other side that I cleaned off with 400 grit paper.
Lovely to hear that Glenn, great job :)
This video have very smooth frames & great lighting. The details are perfect perfect. Beautiful broach. Thanks for shareing.
I don't need a broach, but I want to make one now that I've seen how obvious the procedure is!
I'm impressed. That doesn't happen too often. Good job. I am a ex machinist. I do Solidworks design and CNC programming now. Well, I am unemployed but that's what I have done lately. I always believed machining is a lot of common sense and a little luck. You have both. Thanks for sharing the video. I like it.
Enjoy.........I love it. When I get a lathe , if I ever get half as good as you, I will consider myself a beginner and proud to say I am. Your the best, perfect pace etc
Nice to see you have the tools to broach a subject.
+Andrew Tubbiolo You can pick up a one ton arbor press for around $100, way more than what you need for a hobbyist.
Hey Chris,
Excellent video! The boric acid flux trick is neat. Thanks for sharing.
All the best,
Tom
+oxtoolco Cheers Tom, I appreciate you taking the time to watch :)
oxtoolco ک
oxtoolco bought your books.. good reads
hello sir do you know all designing of broaches like involute
tell y i need help
The quality from production to even the tool is better than most big companies even got, this is incredibly awesome! keep it up man.
+Kim Melin Cheers Kim, appreciate your encouragement
i need to get my hands on some milling equipment. these videos set fire to my imagination.
a couple weeks ago i made a wooden version of the wheel depthing tool thanks to your video. mine is not nearly as fancy or as accurate, but my substrate is wood, so i have a lot more margin of error.
thumbs up yet again!
+KingTesticus Yes you do! Cheers KT, thanks for watching :)
Amazing how often one ends up making their own tools for metal & wood work. Very nice.
+Doug Bourdo So true! Thanks for watching Doug
2 seperate videos in THE SAME MONTH!!!! wow pinch me.
+Kaushik Harith But no video on the clock since Jan. 22. I'm assuming it will be relatively soon since the clock hands (the next clock video) were featured in the spare parts #12 about the bluing process last week.
Weston Means yeah the clock videos are the real deal.he normally puts out the clock video and spare parts video on the same day. Looks like he is changing things up.
Just stumble on your videos. Good education for me just starting out with a new mill and lathe! Thank you for a quality presentation.
why do i watch these videos? i don't do any metalworks myself and still i can't stop watching...
maybe you like the ironside of the man?
why do people watch sports or Olympic competition. People enjoy watching expertise.
Me too. I love great craftmanship. Check out Oxtools too and also Keith Fenner.
.....
Got to say that your videos are great. It is simply a pleasure to watch them. I would just like to ask you to make one video just about tempering the tools where you would explain everything you think is important about tempering. I believe that would mean a lot to hobbyists/amateurs like me.
+TheBlitz667 I will definitely do a full heat treating video as soon as I can, thanks for suggesting and watching :)
7/10. Needs more super-glue arbors.
Love the vids, keep choochin'
+Spooky_Ghost 10/10 would glue again.
Keep yer stick on the ice
+Finn, just Finn. Chooching skookem shmoo
what did you put in a vice
legendary s u p e r g l u e a r b o r s
Chris is an artist!
I didn't knew this tool existed, it's very clever !
Great job Chris !
broaches are how keyways are cut in Internal Diameters.
most. but not all
Very informative ! You should perhaps mention that when quenching, the broach should enter the water exactly vertically to prevent warping, or ending up banana shaped. This is a very useful tool to have, and saves a lot of fileing.I think the sub titles are an excellent idea.
+Englishman French Cheers EF, thanks for watching :)
As always your incredible quality of work and fantastic cinematography make for a wonderful and informative watch. Seeing a video of yours popup on my feed is an awesome moment , It's neat how much work you put into your videos and into the projects themselves, crazy fine work.
Cheers
+Marco Seifert-Simpson Thank you for the kind words Marco, very pleased to have your support :)
Watching your videos is making me want to buy a small mill and lather and start messing around in my garage.
Might I suggest turning the last 14 mm or so round so your broach falls out easily.
+pdgeman Yes good idea, will keep in mind for future, thank you for suggesting
Beating a dead horse after 7 years, but wouldn't the long square end help to brandish the square hole?
Thanks, very nice video! Many good techniques. I smiled when you warned that the broach was fragile. I was doing a part using a 1/4 inch square broach in stainless and was using an arbor press to push it. I was having trouble getting the last bit through and took my hand away from the broach catching position to pull with both hands on the arbor. The broach shot through hit the floor and bounced up breaking in two pieces in mid air! Live and learn!
+William Lee Yes agreed, there's nothing more surprising than watching a piece of hardened steel shatter - its already done the damage, before your mind has processed what the heck happened! Great to have you watching mate :)
Keep up the brilliant work mate! Can't wait to see the clock in all its glory!
+Hyper Paradox Cheers mate, next clock episode on its way soon :)
+Clickspring I can't wait!
I get so excited when i see a new Clickspring video.
+Alex Catto Awesome to hear that Alex, thanks for tuning in each release :)
Yeah, your videos are the best. You must put so much work into them. 👍
How is every bit of kit you use always so clean? Amazing. Great vids. Very enjoyable.
You made that so clear and easy to follow. Thank you for taking the mystery out of it.
Master of his craft.
Just noticed, that your ''tool making videos" are the most watched. Drill, D bit, Files and such. But they are all great.
Amazing work Chris! Love the stuff you make and this is a very nice tool
+Copperbot 10 Cheers mate, thanks for watching :)
+Clickspring Hey Click great job man ! I enjoy your videos the most because the production value is off the charts ... thankyou for all the time and effort you put in !I have one question for you ... Have you done a shop tour video , and if not can you make one for us diehard viewers please :)
+Daniel B. No shop tour yet, but will do one eventually, just want to get the clock over the line first. In the meantime: www.clickspringprojects.com/blog/from-little-things Cheers
Clickspring awesome cant wait :)
thankyou for responding and I will definitely check out your website ! Cheers :)
Chris , all the work you do is beautiful ! It’s like the Hallmark Channel for machinist . Thanks for another great video !
Amazing work! I was in a shop when someone didn't have their broach perpendicular and the press made that thing explode like a shotgun! Made everyone jump.
That square broach is the simplest awesomest tool ive ever seen....
I know this is an old video now, but just saw it. Very well done. Very good quality and sensible for home shop. I've made and modified broaches when I worked as a toolmaker. Have you considered after plunging the spacing cuts to swivel your compound to form an angle on the broach tooth face? I don't remember exact angles but I think 5-10 degrees would do. The gullet should have a small radius in it, maybe about 1/2 the depth so a grooving tool with radius should work. It will give you a sharper cutting edge angle and better chip formation, curling nicely. Also have you used a cat head on a steady rest along with a tailstock center? That should allow you to cut more teeth in one set up. Nicely done sir, I like your bench lathe. Good tip on the Boric acid
at first a tought it will be boring and nonsense... but you make it so didatic and well elaborated what makes me watch everything and say "whut? already ended?"
Very well done dude. SUB!
Terrific to have you watching mate :)
Truly inspiring! That Sherline lathe looks incredibly handy Thanks for sharing!
+Dustin Penner sadly, not something many people ahve in their shops :(
Tim Hyatt Well it's not exactly a unicorn. They are readily available.
+Dustin Penner when the list price is in the $750 to $1500 a pop range, they may as well be unicorns....
Tim Hyatt That's pretty cheap, all things considered.
+Tim Hyatt That's not very expensive. Anyone with an okay income (not even average income) can save up to that. It's similarly priced to a laptop, and $750 is just as much as a Iphone 6s.
It's all about priorities. Maybe not an impulse purchase for most, but almost everyone could get one.
These videos are awesome! I watched the clock compilation and wow! Well done, it keeps people come back for more.
These are so satisfying
Absolutely precise Detailing 5:36 even the mark left behind on metal
You produce some of the best filmed and narrated videos I have seen so far. You have achieved black belt status! Keep up the good work. By the way-- where are you located?
Australia, great to have you watching mate :)
Absolutely beautiful!
Clever tool, thanks for sharing!
+Scrap wood City Cheers mate, appreciate your support :)
Did my apprenticeship making broaches...NAILED IT!
+Tim Cottrell Cheers Tim!
As always, excellent video. Compliments again, Chris, and looking forward to your next video already!
+Tweakwood Cheers mate, new clock episode in the works soon :)
a great easy way to make a broach. my old company used broahes to form the fir tree shapes to attack steam turbine blades to the shaft.
+Mark Gray Thanks for tuning in each release Mark, I appreciate it :)
Chris mate, you never churn out a bad vid! You explain everything so well that even a buffoon like me can understand :D
Cheers!
+Matt Jones Cheers Matt, very much appreciate your support :)
I don't know anything about making tools but this video so relaxing to watch! :)
Shortcuts? ..... you don't seem the guy that makes shortcuts, awesome vid
I consistently have very little understanding of what's actually going on in these videos. But they sure are fascinating to watch.
EXCELLENT Video as always !
Can't help but wonder about the mentality of the 4 people that gave it a 'thumbs down' ???
+oldSawyer
Seems we are currently up to 13 arseholes. It always baffles me too. :/
shoot there are26 idiots now , this is a very informative video and good as well , not to mention the time he took to make it show how one is able to create art for tools 👍
Wow ! . . . Up to 228 Negative Nellies now as of 9-22-18
oldSawyer 229/17k 229 is not worth the ink to wright this down
LOL. . . Seriously ? . . INK on a Computer ? . . Like in the "Dumb Blonde" Joke about how can you tell which computer belongs to the Blonde ? . . . It's The One covered with White-Out !
Another great video. I needed to make a broach and it's been a long time since I last made one. This video was a big help. Thanks!
Terrific to hear that Frank - you've been a huge help to me over the years :)
UA-cam recommendation algorithm at its finest
I can't help but envy how tidy and organised your workshop looks. I'm such a slob haha
I must do this thanks!
I'm in awe of you.
Excellent as always! I work surrounded by these things but never knew how they were made. Of course industrial ones will not be the same, but this is a good explanation of the theory! in a side note, all the broaches in my factory are pushed through instead of pulled. I was surprised because I had always known its better to pull as you mentioned. Thanks for the video!
+Cactus! workshop Yes its definitely safer to pull them through I think, but nobody has the time to build a dedicated broach pull, particularly when we can all pick up a cheap arbor press for a few hundred bucks. Thanks for watching mate, very much appreciate your support :)
hello sir. I am designer of broach designing , i want some more ideas of designing, please help me nd share own experience
I WANT MORE! MORE! MORE!
Слава Богу, ты частее выкладываешь видео! Спасибо!
have you done a video to introduce us to your machine shop tools and tooling? I was a bit surprised with your laith today when you removed the jaws and drive motor, removed a key and then set the assembly back at an angle..
+Paul Gdry Will do a shop tour at some point, in the meantime: www.clickspringprojects.com/blog/from-little-things thanks for watching Paul :)
That two chuck key technique for the four-jaw chuck is great!
AvE would be proud :)
I'm pretty sure you're actually The Doctor, and you're really taking us through making our first TARDIS. But either way, it's interesting as all hell. Thanks Chris!
can you comment about your boric acid mixture?
Sure Nathan - powdered boric acid you can usually get from the hardware store as a roach bait. Mix it with denatured alcohol to form a thick paste. Liberally coat the part to be heated, enough to ensure that it will cover the part once molten. Once the mix melts, it forms a protective glaze over the part, almost completely eliminating oxidation. Once quench is complete, wash off the boric acid residue with boiling water. IMHO, without doubt the most effective heat treating oxidation protection there is for the home shop. Thanks for watching and asking :)
Thanks for the info. Your a life saver
@@Clickspring So just straightforward water quench? Fantastic video, I can't wait to make one. Thanks a million.
Pyro Doll I think he meant to quench the piece in oil, and only use water after that to wash away the borax glaze 🙂
You can also use Silver Solder flux to prevent oxidisation.
Chris, excellent work as usual and the presentation and the video quality is superb! It is always a joy to watch your videos and I truly appreciate the time and effort that you put into making these broadcast quality presentations. Thanks for sharing mate. Cheers!
+Jeffrey Vastine Cheers Jeffrey, terrific to have your support :)