Catalog K

duMONT Minute Man Broaches

Standard and Special Broaches Keyway Broaches and Sets Internal Hole and Surface Broaches

The duMONT Company, LLC, Greenfield, Massachusetts 01302 www.dumont.com

The duMONT Company, LLC

A Reputation for Excellence
MADE in the USA

The duMONT Company, LLC, has been designing and manufacturing Precision Broaches since 1945 Broaches recognized all over the world for quality, durability, and engineering detail. We are the largest supplier of Push-Type Broaches in America, offering Broaches to a wide variety of businesses through a vast national and international distribution network. Our record of design ingenuity, fast delivery, and courteous follow-up is unsurpassed. Materials All duMONT Broaches are manufactured of the finest quality high speed steel. We are equipped to fabricate from a variety of grades to meet your specifications. Contact your industrial distributor or the duMONT Engineering Department for details.

Call Your Industrial Distributor

Your industrial distributor is your best source for Minute Man Broaches. If your regular distributor does not carry duMONT products call us and we will be happy to give you the name of your nearest duMONT distributor. For special technical assistance call the duMONT Engineering Department at 413-773-3674 or 800-628-9648. Fast Delivery An order for stock items placed by your industrial distributor with us by 2PM Eastern Standard Time will almost always be shipped on the same working day.

General Ordering Information

When ordering stock Minute Man Broaches from your distributor please specify EDP No., size, and description to ensure proper fulfillment. Transportation All shipments are made via United Parcel Service where weight limitations allow. Express shipments, both surface and air, are available at your request. Shipments are F.O.B. Greenfield, MA unless otherwise stated. Prices Please contact us for current pricing or refer to current price list for prices on all stock items. Prices are subject to change without notice. TiN or TiAIN Coating All standard items are available with coatings from stock or short delivery. Please contact factory for details.

Warning
Cutting tools may shatter. Eye protection should be worn wherever and whenever cutting tools are being used. Material Safety Data Sheet Available on request or at www.dumont.com.

Ordering Special Broaches

Let Us Meet Your Special Broach Requirements
duMONT Special Broaches can be ordered from your industrial distributor. Before ordering a Special Broach, check to see if a standard item will serve your needs. Using standard items means off-the-shelf delivery and substantially lower cost. When standard items are not appropriate, we would be pleased to design and manufacture a Broach to meet your specific needs. See pp. 2021 for more information on duMONT Special Broaches.

What We Need To Know

A fully dimensioned drawing of the finished part, casting, forging, or Broach would be most helpful. When a part print is unavailable, the following information should be provided: 1. Description of Cut (Size/Shape/Tolerance) 2. Length of Cut 3. Type of Material to be Broached 4. Size and Shape of Hole or Surface to be Broached (For cast holes, give minimum hole size, including draft and fillet radii, if any)

5. For Keyway Broaches Give: a. Minimum Bore Size b. Depth of Keyway Across Bore c. Width of Keyway d. Tolerance 6. Type of Broaching Machine (Push or Pull/Tonnage/Ram Travel/Daylight Opening) 7. Number of Pieces to Broach

The duMONT Company, LLC

289 WELLS STREET, PO BOX 469 GREENFIELD, MASSACHUSETTS 01302 USA TEL. 413-773-3674 or 800-628-9648 FAX 413-773-8430 or 800-331-9957 E-MAIL: info@dumont.com www.dumont.com
Copyright 2012 The duMONT Company, LLC
MADE in the USA

Table of Contents
See Facing Page for General Information
MADE in the USA

26

Broach Sets
duMONT packages the most popular combinations of Keyway Broaches and Bushings in attractive wooden cases, with all necessary Shims included. On hand when you need them for general maintenance or short run production.

710

Keyway Broaches/Bushings/Shims
Individual Broaches, Bushings, and Shims fabricated to precision tolerances in a wide range of inch and metric sizes. For specific applications, short run production, general maintenance, or for replacements in Minute Man Broach Sets.

1112 One-Pass & Production Keyway Broaches

duMONTs One-Pass Broaches offer a cost-effective way to perform short production runs without the need for shims. duMONTs Production Broaches are the fastest way to accomplish high volume production with extreme accuracy cutting keyways in a single pass without Shims or Bushings.

13

Keyseating Broaches, Type AF and AFS

For superior broaching with Hansford-Davis keyseating machines Models 4, 5, and 15. Type AF sizes up to 1 inch and 25mm and Type AFS sizes up to 11/2 inch are in stock. Other inch and metric sizes are readily available.

1415 Pull Type Production Keyway Broaches

A full line of Industry Standard 500 and 600 Series and 5M and 6M Series Keyway Broaches are available.

16

Square Broaches
Standard Square Broaches in the most popular American Standard sizes. Proven design and quality materials ensure superior performance and longer tool life.

17

Full Square and Round Broaches

Full Square Broaches leave no radii on the flats of the broached teeth generating a true square. Round Broaches cut Round holes with far greater accuracy than other methods. All Round Broaches are furnished with variable pitch for greater precision and reduced wear.

18

Hexagon Broaches
Broach precision Hexagon holes with duMONT Hexagon Broaches. Choose from a wide range of stock sizes or take advantage of our extensive capability to design and engineer broaches to your specifications.

19

Metric Square and Hexagon Broaches

Most popular Metric size Square and Hexagon Broaches available from stock.

2021 Special Broaches

Special Broaches to almost any specification in Push or Pull-Types. We can manufacture from your part prints or custom-design for your applications. All types of Keyway, Internal hole, and Surface Broaches in both inch and metric sizes are available.

2224 Engineering Section 25 Presses

Keyway Broach Sets

1/ 16

through 3/8 inch sizes

Applications: Short Run Production General Maintenance

All Minute Man Broach Sets are furnished in handsome varnished wood boxes, and come complete with Precision Broaches, slotted Bushings, and necessary Shims.

No. 00 Precision Set

The most common combinations for small keyways and bores. 3 Broaches and 5 Bushings = 15 Keyway combinations.
Keyway Sizes
1/16, 3/32, 1/8

No. 30 Standard Set

A great starter set. 3 Broaches and 9 Bushings = 15 Keyway combinations.
Keyway Sizes
1/8 3/16 , 1/4

Broach Style

Bushing Diameters (bore sizes)

1/4, 5/16, 3/8, 7/16, 1/2

Broach Style

Bushing Diameters (bore sizes)

1/2, 5/8, 3/4 7/8, 1,

A 11101 Std 11301 TiN

B C 11112 Std 11312 TiN

EDP No.

collared bushings only collared bushings only

11/8, 11/4, 13/8, 11/2

EDP No.

No. 10 Standard Set

Our best selling Broach Set. 4 Broaches and 9 Bushings = 18 Keyway combinations.
Keyway Sizes
1/8, 3/16 1/4, 3/8

collared bushings only collared bushings only

No. 30A Standard Set

Same as No. 30 Set, but for sixteenth-sized bores. 3 Broaches and 9 Bushings = 15 Keyway combinations.
Keyway Sizes
1/8 3/16, 1/4

Broach Style

Bushing Diameters (bore sizes)

1/2, 5/8, 3/4, 7/8

B C 11104 Std 11304 TiN

Broach Style

Bushing Diameters (bore sizes)

9/16, 11/16, 13/16 15/16, 11/16, 13/16, 15/16, 17/16, 19/16

1, 11/8, 11/4, 13/8, 11/2 collared bushings only collared bushings only

B C 11115 Std 11315 TiN

EDP No.

EDP No.

No. 10A Standard Set

Same as No. 10 Set, but for sixteenth-sized bores. 4 Broaches and 9 Bushings = 18 Keyway combinations.
Keyway Sizes
1/8, 3/16 1/4, 3/8

collared bushings only collared bushings only

Broach Style

Bushing Diameters (bore sizes)

9/16, 11/16, 13/16 15/16, 11/16, 13/16, 15/16, 17/16, 19/16

B C 11108 Std 11308 TiN

EDP No.

collared bushings only collared bushings only

Specials
All standard items are available with TiAIN coating from stock or short delivery. Please contact factory for details.

Keyway Broach Sets

1/ 8

through 3/8 inch sizes

Applications: Short Run Production General Maintenance

All Minute Man Broach Sets are furnished in handsome varnished wood boxes, and come complete with Precision Broaches, slotted Bushings, and necessary Shims.

No. 10-10A Combination Set

Combines 10 and 10A Sets. Features all bore sizes in 1/16 inch increments for keyways 1/8 to 3/8 inches. 4 Broaches and 18 Bushings = 36 Keyway combinations.
Keyway Sizes
1/8 3/16 1/4 3/8

No. 30-30A Combination Set

Combines 30 and 30A Sets. Features all bore sizes in 1/16 inch increments. 3 Broaches and 18 Bushings = 30 Keyway combinations.
Keyway Sizes
1/8 3/16 1/4

Broach Style

Bushing Diameters (bore sizes)

1/2, 9/16, 5/8, 11/16, 3/4, 13/16, 7/8

Broach Style

Bushing Diameters (bore sizes)

1/2, 9/16, 5/8, 11/16, 3/4, 13/16 7/8, 15/16, 1, 11/16, 11/8, 13/16, 11/4, 15/16, 13/8, 17/16, 11/2, 19/16

B B C C 11120 Std 11320 TiN

B C C 11124 Std 11324 TiN

1, 11/16, 11/8, 13/16, 1 5 1 /4, 1 /16, 13/8, 17/16, 11/2, 19/16 collared bushings only collared bushings only

15/16,

EDP No.

EDP No.

collared bushings only collared bushings only

No. 20 Combination Set

Same as No. 10-10A Combination Set, but adds a 5/16 inch keyway for 11 extra combinations. 5 Broaches and 18 Bushings = 47 Keyway combinations.
Keyway Sizes
1/8 3/16 1/4 5/16 3/8

Broach Style

Bushing Diameters (bore sizes)

1/2, 9/16, 5/8, 11/16, 3/4, 13/16, 7/8 15/16,

B B C C C 11121 Std 11321 TiN

1, 11/16, 11/8, 13/16, 11/4, 15/16, 13/8, 17/16, 11/2, 19/16

EDP No.

collared bushings only collared bushings only

Specials
All standard items are available with TiAIN coating from stock or short delivery. Please contact factory for details.

Keyway Broach Sets

5/ 16

through 3/4 inch sizes

Applications: Short Run Production General Maintenance

No. 40A Set

The most common keyway combinations for medium-sized keyways and bores. 4 Broaches and 8 Bushings = 32 Keyway combinations.
Keyway Sizes
5/16, 3/8 7/16, 1/2

No. 401/2 A Heavy Duty Set

The most common keyway combinations for large keyways and bores. 2 Broaches and 6 Bushings = 12 Keyway combinations.
Keyway Sizes
5/8 3/4

Broach Style

Bushing Diameters (bore sizes)

Broach Style

Bushing Diameters (bore sizes)

D D 11127 Std 11327 TiN

11/2, 15/8, 13/4, 17/8, 2, 21/8, 21/4, 21/2 plain bushings only plain bushings only

E E 11131 Std 11331 TiN

23/8, 21/2, 25/8, 23/4, 27/8, 3 plain bushings only plain bushings only

EDP No.

EDP No.

No. 40 Set
Same as No. 40A Set, but for sixteenth-sized bores. 4 Broaches and 8 Bushings = 32 Keyway combinations.
Keyway Sizes
5/16, 3/8 7/16, 1/2

No. 401/2 Heavy Duty Set

Same as No. 401/2A Set, but for sixteenth-sized bores. 2 Broaches and 6 Bushings = 12 Keyway combinations.
Keyway Sizes
5/8 3/4

Broach Style

Bushing Diameters (bore sizes)

Broach Style

Bushing Diameters (bore sizes)

D D 11129 Std 11329 TiN

17/16, 19/16, 111/16, 113/16, 115/16, 23/16, 27/16, 215/16 plain bushings only plain bushings only

E E 11133 Std 11333 TiN

25/16, 27/16, 29/16, 211/16, 213/16, 215/16 plain bushings only plain bushings only

EDP No.

EDP No.

Specials
All standard items are available with TiAIN coating from stock or short delivery. Please contact factory for details.

Keyway Broach Sets

1/ 8

through 3/4 inch sizes

Applications: Virtually all standard broaching operations our most complete set

No. 50 Heavy Duty Set

Includes the most common keyway combinations for medium and large keyways. 3 Broaches and 17 Bushings = 29 Keyway combinations.
Keyway Sizes
1/2 5/8 3/4

No. 100 Heavy Duty Combination Set

The most complete Minute Man Broach Set available; including all popular combinations without duplication. This set is furnished in three handsome varnished wood boxes for convenient handling and storage, and comes with Broaches, slotted Bushings, and necessary Shims. 9 Broaches and 44 Bushings = 102 Keyway combinations.
Keyway Sizes
1/8 3/16 1/4 5/16 3/8 7/16 1/2 5/8 3/4

Broach Style

Bushing Diameters (bore sizes)

D E E 11135 Std 11335 TiN

2, 21/16, 21/8, 23/16, 21/4 25/16, 23/8, 27/16, 21/2, 29/16, 25/8, 211/16, 23/4, 213/16, 27/8, 215/16, 3 plain bushings only plain bushings only

Broach Style

Bushing Diameters (bore sizes)

1/2, 9/16, 5/8, 11/16, 3/4, 13/16, 7/8 15/16,

EDP No.

B B C C D D D E E 11136 Std 11336 TiN

15/16,

1, 11/16, 11/8, 13/16, 11/4, 13/8, 17/16, 11/2, 19/16

17/16, 11/2, 19/16, 15/8, 111/16, 13/4, 113/16, 17/8, 115/16, 2, 21/16, 21/8, 23/16, 21/4 25/16, 23/8, 27/16, 21/2, 29/16, 25/8, 211/16, 23/4, 213/16, 27/8, 215/16, 3 collared B and C bushings, plain D and E bushings collared B and C bushings, plain D and E bushings

EDP No.

Specials
All standard items are available with TiAIN coating from stock or short delivery. Please contact factory for details.

Metric Keyway Broach Sets

2mm through 18mm (I.S.O.)

Applications: Short Run Production General Maintenance

No. 60 Metric Set

The most common metric keyway combination for small keyways and bores. 2 Broaches and 3 Bushings = 6 Keyway combinations.
Keyway Sizes Broach Style Bushing Diameters (bore sizes)

No. 80 Metric Set

The most common metric keyway combination for medium-sized keyways and bores. 3 Broaches and 12 Bushings = 36 Keyway combinations.
Keyway Sizes Broach Style Bushing Diameters (bore sizes)

2mm 3mm EDP No.

A A 44497 Std 44397 TiN

6, 8, 10 collared bushings only collared bushings only

10mm 12mm 14mm EDP No.

D D D 44499 Std 44399 TiN

32, 34, 35, 36, 38, 40, 42, 44, 45, 46, 48, 50 plain bushings only plain bushings only

No. 70 Metric Set

Our most popular metric broach set. 4 Broaches and 13 Bushings = 26 Keyway combinations.
Keyway Sizes Broach Style Bushing Diameters (bore sizes)

No. 90 Metric Set

The most common metric keyway combination for large keyways and bores. 2 Broaches and 8 Bushings = 16 Keyway combinations.
Keyway Sizes Broach Style Bushing Diameters (bore sizes)

4mm 5mm 6mm 8mm EDP No.

B1 B1 C C 44498 Std 44398 TiN

12, 14, 15, 16 18, 19, 20, 22, 24, 25, 26, 28, 30 collared bushings only collared bushings only

16mm 18mm EDP No.

E E 44500 Std 44300 TiN

52, 54, 55, 56, 58, 60, 62, 65 plain bushings only plain bushings only

Specials
All standard items are available with TiAIN coating from stock or short delivery. Please contact factory for details.

Keyway Broaches
1/ 16

through 11/2 inch sizes

Applications: Short Run Production General Maintenance

Stock Keyway Broaches

Broaches are supplied with necessary Shims unless otherwise noted. For extra or replacement Shims see the table below. Std EDP No. 22201 22202 22203 22204 22205 22206 22207 22208 22209 22210 22211 22212 22213 22214 22215 10142 22216 22217 22218 22219 10171 10172 10173 10174 TiN EDP No. 22301 22302 22303 22304 22305 22306 22307 22308 22309 22310 22311 22312 22313 22314 22315 10342 22316 22317 22318 22319 TiAlN EDP No. 22801 22802 22803 22804 22805 22806 22807 22808 22809 22810 22811 22812 22813 22814 22815 10842 22816 22817 22818 22819 Broach Size
1/16-A 3/32-A 1/8-A 3/32-B 1/8-B 5/32-B 3/16-B 3/16-C 1/4-C 5/16-C 3/8-C 5/16-D 3/8-D 7/16-D 1/2-D 9/16-D 5/8-E 3/4-E 7/8-F

Tolerances .0625 - .0635 .0938 - .0948 .1252 - .1262 .0938 - .0948 .1252 - .1262 .1564 - .1574 .1877 - .1887 .1877 - .1887 .2502 - .2512 .3127 - .3137 .3755 - .3765 .3127 - .3137 .3755 - .3765 .4380 - .4390 .5006 - .5016 .5631 - .5641 .6260 - .6270 .7515 - .7525 .8765 - .8775 1.0015 -1.0025 1.1265 -1.1275 1.2520 -1.2530 1.3770 -1.3780 1.5020 -1.5030

Broach Dimensions
1/8 x 1/8 x 3/16 x 3/16 x

Shims Reqd. 0 0 1 0 1 1 1 1 1 2 2 2 2 3 3 4 4 5 6 7 8 9 10** 11**

Length of Cut* Min. & Max.

13/64 13/64 13/64 19/64 19/64 19/64 19/64 25/64 25/64 25/64 25/64

Pressure Reqd. for Max. L/C* 390 lbs. 780 650 930 720 1320 1860 1540 2520 3960 4340 8000 7000 9400 9800 8900 9600 11900 9800 11100 14750 22100 23500 26500

5 5 1/8 x 5 63/4 63/4 3/16 x 63/4 3/16 x 63/4

3/8 3/8

11/8 11/8 11/8 111/16 111/16 111/16 111/16 21/2 21/2 21/2 21/2 6 6 6 6 6 6 6 6 6 6 8 8 8

x 113/4 x 113/4 3/8 x 113/4 3/8 x 113/4

9/16 9/16

x 137/8 x 137/8 9/16 x 137/8 9/16 x 137/8 9/16 x 137/8

3/4 x 3/4 x

1 1 1 1 1 1 1 1 1 1 11/2 11/2 11/2

151/2 151/2

1-F 11/8 11/4 13/8 11/2

1 x 201/4 1 x 201/4 11/8 x 201/4 11/4x 201/4 13/8 x 201/4 11/2 x 201/4
*Based on mild steel

Extra Shims

**Shims are not supplied with these Broaches

Extra Shims are provided in necessary Shim Sets only. For Broaches larger than 11/4" progressive Shims are available as special items. Please specify EDP No. when ordering extra or replacement Shims. Shims correspond to Broach size, not to Bushing type. EDP No. 22250 22252 22253 22254 22255 22256 Broach Size 1/8-A 1/8-B 5/32-B 3/16-B 3/16-C 1/4-C Shim #/Set Thickness 1 .031 1 .031 1 .042 1 .050 1 .050 1 .0625 EDP No. 22257 22258 22259 22260 22261 22262 22269 Broach Size 5/16-C 3/8-C 5/16-D 3/8-D 7/16-D 1/2-D 9/16-D Shim #/Set Thickness 2 .055 2 .0625 2 .056 2 .0625 3 .056 3 .0625 4 .056 Shim #/Set Thickness 4 .0625 5 .0625 6 .0625 7 .0625 8 .0625 9 .0625 1 For Broaches larger than 1 /4" Progressive
Shims are available as special items.

EDP No. 22263 22264 22265 22266 22267 22268

Broach Size 5/8-E 3/4-E 7/8-F 1-F 11/8 11/4

Specials
7

We are fully equipped to manufacture Special Keyway Broaches not listed above. TiN or TiAIN coatings are available. Please contact factory for details.

Keyway Bushings
Bushing Styles A through F Keyway Bushings
duMONT Keyway Bushings enable the operator to use individual Keyway Broaches in a variety of bore sizes. Both Bushings and Broaches are designated by a letter which signifies the width of the Keyway Broach and Bushing opening. For proper fit, use Bushings with the same letter designation as the Broach being used i.e. A Bushings with A Broaches, B Bushings with B Broaches, etc.

Applications: To use Keyway Broaches in various bore sizes

A Bushings for A Broaches

Dia.
1/4 5/16 3/8 7/16 1/2

D Bushings for D Broaches

Dia. 17/16 11/2 19/16 15/8 111/16 13/4 113/16 17/8 115/16 2 21/16 21/8 23/16 21/4 25/16 23/8 27/16 21/2 29/16 25/8 211/16 23/4 213/16 27/8 215/16 3 EDP No. Length Plain Only 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 33348 33349 33350 33351 33352 33353 33354 33355 33356 33357 33358 33359 33360 33361 33362 33363 33364 33365 33366 33367 33368 33369 33370 33371 33372 33373

Length 11/8 11/8 11/8 11/8 11/8

EDP No. Collared Only 33301 33302 33303 33304 33305

E Bushings for E Broaches

Dia. 25/16 23/8 27/16 21/2 29/16 25/8 211/16 23/4 213/16 27/8 215/16 3 31/16 31/8 33/16 31/4 35/16 33/8 37/16 31/2 39/16 35/8 311/16 33/4 313/16 37/8 315/16 4 EDP No. Length Plain Only 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 33374 33375 33376 33377 33378 33379 33380 33381 33382 33383 33384 33385 33386 33387 33388 33389 33390 33391 33392 33393 33394 33395 33396 33397 33398 33399 33400 33401

F Bushings for F Broaches

Dia. 31/16 31/8 33/16 31/4 35/16 33/8 37/16 31/2 39/16 35/8 311/16 33/4 313/16 37/8 315/16 4 41/16 41/8 43/16 41/4 45/16 43/8 47/16 41/2 49/16 45/8 411/16 43/4 413/16 47/8 415/16 5 EDP No. Length Plain Only 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 33500 33501 33502 33503 33504 33505 33506 33507 33508 33509 33510 33511 33512 33513 33514 33515 33516 33517 33518 33519 33520 33521 33522 33523 33524 33525 33526 33527 33528 33529 33530 33531

B Bushings for B Broaches

Dia.
1/2 9/16 5/8 11/16 3/4 13/16 7/8

Length 111/16 111/16 111/16 111/16 111/16 111/16 111/16

EDP No. Collared Only 33313 33314 33315 33316 33317 33318 33319

C Bushings for C Broaches

Dia.
3/4 13/16 7/8 15/16

Length 21/2 21/2 21/2 21/2 21/2 21/2 21/2 21/2 21/2 21/2 21/2 21/2 21/2 21/2

EDP No. Collared Only 33334 33335 33336 33337 33338 33339 33340 33341 33342 33343 33344 33345 33346 33347

1 11/16 11/8 13/16 11/4 15/16 13/8 17/16 11/2 19/16

Specials
We are fully equipped to manufacture Special Bushings not listed above. Please contact factory for details.

Metric Keyway Broaches

2mm through 45mm (I.S.O.)

Applications: Short Run Production General Maintenance

Stock Keyway Broaches

Broaches are supplied with necessary Shims unless otherwise noted. For extra or replacement Shims see the table below. Std EDP No. 44401 44402 44403 44404 44405 44406 10232 44407 44408 44409 44410 44411 44412 44413 44414 44415 44494 10233 10234 10235 10236 10237 TiN EDP No. 44301 44302 44303 44304 44305 44306 10332 44307 44308 44309 44310 44311 44312 44313 44314 44315 44394 TiAlN EDP No. 44801 44802 44803 44804 44805 44806 10832 44807 44808 44809 44810 44811 44812 44813 44814 44815 44894 Broach Size mm 2-A 3-A 4-B1 5-B1 5-C 6-C 7-C 8-C 10-D 12-D 14-D 16-E 18-E 20-F 22-F 24-F 25-F 28 32 36 40 45 Tolerances (Decimal Equiv.) .0782 - .0791 .1176 - .1185 .1569 - .1579 .1963 - .1972 .1963 - .1972 .2356 - .2366 .2749 - .2763 .3143 - .3155 .3930 - .3942 .4716 - .4730 .5503 - .5517 .6290 - .6304 .7078 - .7092 .7864 - .7880 .8651 - .8667 .9439 - .9455 .9832 - .9848 1.1025 - 1.1035 1.2600 - 1.2610 1.4175 - 1.4185 1.5753 - 1.5760 1.7718 - 1.7728 Broach Dimensions in Inches
1/8 1/8 1/4 1/4 3/8 3/8

Standard Millimeter Shims Length of Cut* Keys Reqd. Min. & Max. 2x2 3x3 4x4 5x5 5x5 6x6 7x6 8x7 10 x 8 12 x 8 14 x 9 16 x 10 18 x 11 20 x 12 22 x 14 24 x 14 25 x 14 28 x 16 32 x 18 36 x 20 40 x 22 45 x 25 0 1 1 1 1 1 1 2 2 2 2 3 3 3 4 5 4 5 5 7** 7** 8**
13/64 13/64 19/64 19/64 25/64 25/64 25/64 25/64

Pressure Reqd. for Max. L/C* 720 lbs. 650 1140 1860 1470 2100 2900 3680 6500 8400 11100 9400 10600 8800 9400 10600 12300 12000 20600 24200 22500 27200

x5 x5 x 63/4 x 63/4

11/8 11/8 111/16 111/16 21/2 21/2 21/2 21/2 6 6 6 6 6 6 6 6 6 6 8 8 8 8

x 113/4 x 113/4 3/8 x 113/4 3/8 x 113/4

9/16 9/16

x 137/8 x 137/8 9/16 x 137/8

3/4 3/4

1 1 1 1 1 1 1 1 1 1 11/2 11/2 11/2 11/2

x 151/2 x 151/2

1 x 201/4 1 x 201/4 1 x 201/4 1 x 201/4 11/8 x 201/4 11/4 x 201/4 17/16 x 201/4 19/16 x 201/4 13/4 x 201/4

Extra Shims

*Based on mild steel

**Shims are not supplied with these Broaches

Extra Shims are provided in necessary Shim Sets only. For Broaches larger than 32mm, progressive Shims are available as special items. Please specify EDP No. when ordering extra or replacement Shims. Shims correspond to Broach Size, not to Bushing type. Broach EDP No. Size mm 44480 44481 44482 44483 44484 44577 44485 3-A 4-B1 5-B1 5-C 6-C 7-C 8-C Shim #/Set Thickness 1 1 1 1 1 1 2 .031 .038 .050 .047 .0625 .0625 .050 Broach EDP No. Size mm 44486 44487 44488 44489 44490 10-D 12-D 14-D 16-E 18-E Shim #/Set Thickness 2 2 2 3 3 .056 .056 .0625 .056 .056 Broach EDP No. Size mm 44491 44492 44493 44496 44478 44479 20-F 22-F 24-F 25-F 28 32 Shim #/Set Thickness 3 4 5 4 5 5 .0625 .056 .0625 .056 .056 .0625

For Broaches larger than 32mm Progressive Shims are available as special items.

Specials
We are fully equipped to manufacture Special Keyway Broaches not listed above. TiN or TiAIN coatings are available. Please contact factory for details.

Metric Keyway Bushings

Bushing Styles A through F

Applications: To use metric Keyway Broaches in various metric bore sizes Metric Keyway Bushings
duMONT Metric Keyway Bushings enable the operator to use individual Metric Keyway Broaches in a variety of bore sizes. Both Bushings and Broaches are designated by a letter which signifies the width of the Keyway Broach and Bushing opening. For proper fit, use Bushings with the same letter designation as the Broach being used i.e. Metric A Bushings with Metric A Broaches, Metric B1 Bushings with Metric B1 Broaches, etc.

A Bushings for A Broaches

Dia. mm 6 8 10 12 15 Dec. Equiv. .2362 .315 .3937 .4724 .5905 EDP No. Collared Only 44501 44431 44432 44502 44503

B1 Bushings for B1 Broaches

Dia. mm 12 14 15 16 17 18 19 Dec. Equiv. .4724 .5512 .5905 .6299 .6693 .7087 .7480 EDP No. Collared Only 44433 44434 44504 44435 44505 44436 44506

C Bushings for C Broaches

Dia. mm 18 19 20 22 24 25 26 28 30 32 34 35 36 Dec. Equiv. .7087 .7480 .7874 .8661 .9449 .9842 1.0236 1.1024 1.1811 1.2598 1.3386 1.3779 1.4173 EDP No. Collared Only 44437 44438 44439 44440 44441 44442 44443 44444 44445 44446 44447 44507 44448

D Bushings for D Broaches

Dia. mm 32 34 35 36 38 40 42 44 45 46 48 50 52 54 56 Dec. Equiv. 1.2598 1.3386 1.3779 1.4173 1.4961 1.5748 1.6535 1.7323 1.7716 1.8110 1.8898 1.9685 2.0472 2.1260 2.2047 EDP No. Plain Only 44449 44450 44451 44452 44453 44454 44455 44456 44457 44458 44459 44460 44461 44462 44463

E Bushings for E Broaches

Dia. mm 52 54 55 56 58 60 62 63 64 65 66 68 70 72 Dec. Equiv. 2.0472 2.1260 2.1653 2.2047 2.2835 2.3622 2.4409 2.4803 2.5197 2.5590 2.5984 2.6772 2.7559 2.8346 EDP No. Plain Only 44464 44465 44466 44467 44468 44469 44470 44471 44472 44473 44474 44475 44476 44477

F Bushings for F Broaches

Dia. mm 75 80 85 90 95 100 105 110 115 120 Dec. Equiv. 2.9527 3.1496 3.3464 3.5433 3.7401 3.9370 4.1338 4.3307 4.5275 4.7244 EDP No. Plain Only 44540 44541 44542 44543 44544 44545 44546 44547 44548 44549

Specials
We are fully equipped to manufacture Special Bushings not listed above. Please contact factory for details.

10

One-Pass Broaches
1/ 8

through 8 inch sizes 3mm through 14mm (I.S.O.)

3/

Applications: High Speed Operation Accurate Small Run Production

One-Pass Keyway Broaches

duMONT Minute Man One-Pass Keyway Broaches are designed for smaller production runs of identical keyways in varying bores. Used with the appropriate Bushing size (American Standard or Metric) and Style (see pages 8 and 10) to cut to full width and depth in one-pass, no shimming required. Reminder Broach and Bushing Style must match A Broaches with A Bushings, B Broaches with B Bushings, etc. A special chamfering feature that will deburr the keyway while it is being broached is also available. TiN or TiAIN coatings available.

Stock One-Pass Broaches Inch

EDP No. 55507 55508 55509 55501 55502 55503 55504 55505 55506 Broach Size
1/8-B 5/32-B 3/16-B 1/8-C 5/32-C 3/16-C 1/4-C 5/16-C 3/8-C

Broach Dimensions
3/16 3/16 3/8 3/8 3/8 3/8

Tooth Pitch
1/4 1/4 1/4 9/32 9/32 9/32 9/32 9/32 9/32

Length of Cut* Min. & Max.

19/64 19/64 19/64 19/64 19/64 19/64 19/64 19/64 19/64

Pressure Reqd. for Max. L/C* 800 lbs. 1450 2050 900 1360 1570 2560 3900 5300
*Based on mild steel

x 103/4 x 103/4 3/16 x 103/4 x 141/8 x 141/8 3/8 x 17 x 17 x 181/2 3/8 x 181/2

111/16 111/16 111/16 2 2 2 2 2 2

Stock One-Pass Broaches Metric

EDP No. 55510 55511 55512 55513 55514 55515 55516 55517 Broach Size mm 3-A 4-B1 5-B1 6-C 8-C 10-D 12-D 14-D Broach Dimensions
1/8 1/4 3/8 3/8 9/16 9/16

Tooth Pitch
3/16 1/4 1/4 9/32 5/16 3/8 3/8 3/8

Length of Cut* Min. & Max.

13/64 3/8 3/8 3/8 3/8 25/64 25/64 25/64

Pressure Reqd. for Max. L/C* 675 lbs. 1550 2430 2240 3485 3410 4220 5670
*Based on mild steel

x 73/4 x 103/4 1/4 x 103/4 x 17 x 181/2

1 15/8 15/8 13/4 2 2 2 2

x 24 x 24 9/16 x 24

Specials
We are fully equipped to manufacture Special One-Pass Broaches to your specifications. A special chamfering feature that will deburr the keyway while it is being broached is also available. All standard items are available with TiN or TiAIN coatings from stock or short delivery. Please contact factory for details.

11

Production Keyway Broaches

Push-Type Keyway Broaches

Applications: High Speed Operation Accurate Long Run Production

Production Broach Construction

Shoulders and back are form-ground to fit bore. These 3 supporting surfaces extend the full length of the broach.

Production Keyway Broaches

Minute Man Production Keyway Broaches offer maximum speed and accuracy in production runs of identical bores, using either hydraulic or hand-operated presses. These Broaches are self-supporting no Shims or Bushings are required.

Stock Production Keyway Broaches

Production Keyway Broaches are designed for large production runs of identical keyways with identical bores. No Shims or Bushings required. A special chamfering feature that will deburr the keyway while it is being broached is also available. TiN or TiAIN coatings available. Pressure Reqd for Max. L/C* 390 lbs. 390 850 1440 1440 1440 2170 2170 2170 2870 1550
*Based on mild steel

EDP No. 55520 55521 55522 55523 55524 55525 55526 55528 55530 55532 55533

Keyway Width
1/16 1/16 1/8 1/8 1/8 1/8 3/16 3/16 3/16 1/4

Body Diameter
3/16 1/4 3/8 1/2 9/16 5/8 5/8 3/4 7/8

A Dimension .224 .287 .437 .565 .630 .693 .716 .844 .970 1.121 11.9mm .468

Broach Length 55/8 63/16 81/2 113/4 113/4 113/4 143/4 143/4 143/4 18 12

Tooth Pitch
3/16 3/16 1/4 3/8 3/8 3/8 3/8 3/8 3/8 3/8 9/32

Length of Cut* Min. & Max.

13/64 13/64 17/64 25/64 25/64 25/64 25/64 25/64 25/64 25/64 19/64

1 1 11/4 21/2 21/2 21/2 21/2 21/2 21/2 21/2 17/8

1 10mm

4mm

Specials
We are fully equipped to manufacture Special Production Style Broaches to your specifications. A special chamfering feature that will deburr the keyway while it is being broached is also available. All standard items are available with TiN or TiAIN coatings from stock or short delivery. Please contact factory for details.

12

Keyseating Broaches
1/ 16

through inch sizes 2mm through 25mm (I.S.O.)

11/2

Applications: For Hansford Davis Keyseating machine Modes 4, 5, and 15

Stock Keyseating Broaches, Type AF

Minute Man Keyseating Broaches feature superior tooth design and are ground to precision keyway tolerances. Sizes for cutting the most common keyway widths are available. TiN or TiAIN coatings available.

Type AF Inch
EDP No. 55550 55551 55552 55553 55554 55555 55556 55557 55558 55559 55560 55561 55562 55563 55564 55565 55566 55567 Broach Size
1/16* 3/32* 1/8* 5/32 3/16 1/4 1/4 5/16 5/16 3/8 3/8 7/16 1/2 9/16 5/8 3/4 7/8

Overall Length 16 16 16 16 16 16 20 16 20 16 20 20 20 20 20 20 20 20

Tooth Height
3/8 3/8 7/16 1/2 9/16 3/4 3/4 7/8 7/8 7/8 7/8

Tooth Pitch
3/8 3/8 3/8 3/8 3/8 3/8 3/8 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32

Type AF Metric Standard (I.S.O.)

EDP No. 55570 55571 55572 55573 55574 55575 55576 55577 55578 55579 55580 55581 55582 55583 55584 55585 55586 55587 55588 55589 55590 55591 55592 55593 55594 55595 Broach Size 2mm* 3mm* 4mm 5mm 6mm 6mm 7mm 7mm 8mm 8mm 9mm 9mm 10mm 11mm 12mm 13mm 14mm 15mm 16mm 17mm 18mm 19mm 20mm 22mm 24mm 25mm Overall Length 16 16 16 16 16 20 16 20 16 20 16 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 Tooth Height
3/8 7/16 1/2 9/16 3/4 3/4 7/8 7/8 7/8 7/8 7/8 7/8 7/8

Tooth Pitch
3/8 3/8 3/8 3/8 3/8 3/8 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32 17/32

1 1 1 1 1 1 1

*Reinforced body width 3/16" thick

Stock Keyseating Broaches, Type AFS

Staggered Tooth AFS Type Keyseating Broaches provide a stagger tooth design, promoting an efficient cut. TiN or TiAIN coatings available.

Type AFS Inch

EDP No. 55601 55602 55603 55604 55605 55606 55607 55608 55609 55610 55611 55612 Broach Size
3/8 3/8 7/16 1/2 9/16 5/8 3/4 7/8

Overall Length 20 20 20 20 20 20 20 20 20 20 20 20

Tooth Height 1 11/2 1 1 1 1 1 1 1 13/4 13/4 13/4

Tooth Pitch
17/32 3/4 17/32 17/32 17/32 17/32 17/32 17/32 17/32 3/4 3/4 3/4

1 1 1 1 1 1 1 1 1 1 1 1 1

*Reinforced body width 3/16" thick

1 11/8 11/4 11/2

Specials
We are fully equipped to manufacture Special Keyseating Broaches not listed above. All standard items are available with TiN or TiAIN coatings from stock or short delivery. Please contact factory for details.

13

Pull-Type Keyway Broaches

Industry Standard 500 and 600 Series 1/ 16 through 1 inch sizes

Applications: For high volume production pull-type machines

Industry Standard 500 and 600 Series

duMONT Minute Man offers the most common American Standard (1/161") Pull-Type Keyway Broaches for use in high volume production. Available either as Industry Standard 500 Series with threaded pull end or 600 Series with notched pull end. EDP No. 500 Series 10501 10502 10503 10504 10505 10506 10507 10508 10509 10510 10511 10512 10513 10514 10515 10516 10517 10518 10519 10520 10521 10522 10523 10524 10525 10526 10527 10528 10529 10530 10531 10532 10533 10534 10535 10536 10537 10538 10539 EDP No. A 600 Nom. Decimal Series Dim. Dim. 10601 10602 10603 10604 10605 10606 10607 10608 10609 10610 10611 10612 10613 10614 10615 10616 10617 10618 10619 10620 10621 10622 10623 10624 10625 10626 10627 10628 10629 10630 10631 10632 10633 10634 10635 10636 10637 10638 10639
1/16 3/32 3/32 1/8 1/8 5/32 5/32 3/16 3/16 7/32 7/32 1/4 1/4 1/4 9/32 9/32 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 9/16 5/8 5/8 5/8 3/4 3/4 3/4 7/8 7/8 7/8

Min. Hole Size

3/8 7/16 9/16 1/2 11/16 19/32 23/32 11/16 7/8 11/16 15/16 3/4 1 13/8 7/8 11/4 11/16 15/16 11/16 15/16 19/16 13/4 11/2 19/16 111/16 15/8 115/16 17/8 115/16 115/16 115/16 21/16 21/16 21/4 21/8 21/8 21/4 21/4 21/4

Min. Length Cut#

3/8 1/2 5/8 1/2 5/8 1/2 5/8 5/8 11/16 5/8 11/16 5/8 11/16 7/8 11/16 7/8 11/16 7/8 11/16 7/8 11/16

Max. Length Cut* 11/4 11/2 21/2 11/2 21/2 11/2 21/2 21/2 31/2 21/2 31/2 21/2 4 6 4 6 4 6 4 6 4 8 4 8 4 8 12 4 8 12 4 8 12 4 8 12 21/2 6 12

B .1552 .1865 .2490 .2490 .3115 .2490 .3115 .3740 .3740 .3740 .3740 .3740 .4990 .6240 .4990 .4990 .4990 .4990 .4990 .4990 .6240 .6240 .6240 .6240 .6865 .6865 .8740 .7490 .8740 .8740 .8740 .9990 .9990 1.1240 1.1240 1.1240 1.2490 1.2490 1.2490

C 20 24 33 30 33 30 33 36 36 33 42 36 45 51 42 51 45 51 45 54 48 48 48 48 54 51 60 60 54 60 60 60 60 63 63 63 63 63 63

D .313 .367 .491 .438 .594 .525 .625 .581 .796 .557 .813 .612 .877 1.250 .716 1.093 .908 1.158 .938 1.189 1.390 1.611 1.312 1.377 1.438 1.391 1.641 1.625 1.657 1.657 1.625 1.688 1.688 1.875 1.719 1.719 1.750 1.750 1.750

E .271 .309 .433 .364 .520 .436 .536 .476 .691 .437 .693 .476 .741 1.114 .564 .941 .741 .991 .739 .990 1.160 1.496 1.051 1.246 1.146 1.245 1.495 1.301 1.495 1.495 1.239 1.495 1.560 1.426 1.494 1.569 1.239 1.494 1.580

F 713/16 81/4 10 9 10 9 10 10 1011/16 10 111/16 10 12 133/4 115/8 131/2 12 133/4 12 131/2 12 155/8 12 161/2 1113/16 16 20 12 163/8 20 12 161/4 20 123/8 153/4 20 101/2 141/4 20

G .042 .058 .058 .074 .074 .089 .089 .105 .105 .120 .120 .136 .136 .136 .152 .152 .167 .167 .199 .199 .230 .230 .261 .261 .292 .292 .292 .324 .324 .324 .386 .386 .386 .449 .449 .449 .511 .511 .511

No. of Thread Cuts Size 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 2 1 2 2 1 2 3 1 2 3 1 2 3 - 20 - 18 - 16 3/8 - 16 1/2 - 13 3/8 - 16 1/2 - 13 1/2 - 13 1/2 - 13 1/2 - 13 1/2 - 13 1/2 - 13 5/8 - 11 3/4 - 10 5/8 - 11 5/8 - 11 5/8 - 11 5/8 - 11 5/8 - 11 5/8 - 11 3/4 - 10 3/4 - 10 3/4 - 10 3/4 - 10 1-8 1-8 1-8 1-8 1-8 1-8 1-8 11/4 - 7 11/4 - 7 11/4 - 7 11/4 - 7 11/4 - 7 11/2 - 6 11/2 - 6 11/2 - 6
1/4 5/16 3/8

1 1 1

.0635 .0948 .0948 .1260 .1260 .1572 .1572 .1885 .1885 .2198 .2198 .2510 .2510 .2510 .2828 .2828 .3140 .3140 .3765 .3765 .4390 .4390 .5015 .5015 .5645 .5645 .5645 .6270 .6270 .6270 .7520 .7520 .7520 .8770 .8770 .8770 1.0020 1.0020 1.0020

1
11/16

1
11/16 1 11/8 11/16 1 11/8 11/16 1 11/8 11/16 1 11/8 5/8 7/8 11/8

Tolerance - Based on +/-.0005

# Minimum length of part recommended to prevent part from dropping in between broach teeth *Based on mild steel

Specials
We are fully equipped to manufacture Special Pull-Type Keyway Broaches to your specifications. A special chamfering feature that will deburr the keyway while it is being broached is also available. All standard items are available with TiN or TiAIN coatings from stock or short delivery. Please contact factory for details. 14

Pull-Type Keyway Broaches

Industry Standard 5M and 6M Series 2mm through 25mm (I.S.O.) Industry Standard Metric 5M and 6M Series

Applications: For high volume production pull-type machines

duMONT Minute Man offers the most common Metric (225mm) Pull-Type Keyway Broaches for use in high volume production. Available either as Industry Standard 5M Series with threaded pull end or 6M Series with notched pull end. See image page 14. EDP No. EDP No. A 5M 6M Nom. Decimal Series Series Dim. Dim. 10561 10562 10563 10564 10565 10566 10567 10568 10569 10570 10571 10572 10573 10574 10575 10576 10577 10578 10579 10580 10581 10582 10583 10584 10585 10586 10661 10662 10663 10664 10665 10666 10667 10668 10669 10670 10671 10672 10673 10674 10675 10676 10677 10678 10679 10680 10681 10682 10683 10684 10685 10686 2 3 4 4 5 5 6 6 8 8 10 10 12 12 14 14 16 16 18 18 20 20 22 22 25 25 .0792 .1186 .1581 .1581 .1974 .1974 .2368 .2368 .3157 .3157 .3944 .3944 .4733 .4733 .5520 .5520 .6308 .6308 .7095 .7095 .7884 .7884 .8672 .8672 .9853 .9853 Min. Hole Size 9 .354 11 .433 13 .512 13 .512 14 .551 23 .906 18 .709 26 1.024 27 1.063 33 1.299 27 1.063 36 1.417 39 1.535 39 1.535 40 1.575 44 1.732 47 1.850 48 1.890 48 1.890 51 2.008 56 2.205 53 2.087 57 2.244 53 2.087 56 2.205 56 2.205 Min. Max. Length Length Cut# Cut* 9.5 3/8 12.7 1/2 12.7 1/2 15.9 5/8 14.3 9/16 15.9 5/8 15.9 5/8 17.5 11/16 17.5 11/16 22.2 7/8 17.5 11/16 22.2 7/8 17.5 11/16 25.4 1 17.5 11/16 25.4 1 17.5 11/16 28.6 11/8 17.5 11/16 28.6 11/8 17.5 11/16 28.6 11/8 17.5 11/16 28.6 11/8 17.5 11/16 28.6 11/8 31.8 11/4 38 11/2 38 11/2 63.5 21/2 44.5 13/4 76.2 3 63.5 21/2 102 4 102 4 152 6 102 4 152 6 102 4 203 8 102 4 203 8 102 4 305 12 102 4 305 12 102 4 305 12 102 4 305 12 102 4 305 12 No. of Thread Cuts Size 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1
1/4 5/16 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4 3/4 3/4

B 3.942 .1552 4.737 .1865 6.325 .249 6.325 .249 7.91 .3115 9.5 .374 9.5 .374 12.67 .499 12.67 .499 12.67 .499 12.67 .499 15.85 .624 15.85 .624 15.85 .624 17.44 .6865 19.02 .749 19.02 .749 22.2 .874 22.2 .874 25.37 .999 28.55 1.124 28.55 1.124 28.55 1.124 28.55 1.124 31.72 1.249 31.72 1.249

C 508 20 610 24 838 33 915 36 915 36 1067 42 915 36 1143 45 1143 45 1295 51 1143 45 1295 51 1219 48 1524 60 1372 54 1524 60 1524 60 1524 60 1524 60 1524 60 1600 63 1600 63 1600 63 1600 63 1600 63 1600 63

D 7.95 .313 9.32 .367 11.13 .438 11.07 .436 11.07 .436 20.65 .813 15.54 .612 22.28 .877 23.06 .908 29.41 1.158 23.27 .916 31.75 1.250 34.06 1.341 34.06 1.341 34.39 1.354 38.33 1.509 41.28 1.625 41.28 1.625 41.28 1.625 42.88 1.688 47.63 1.875 43.66 1.719 47.63 1.875 43.66 1.719 44.45 1.750 44.45 1.750

G 1.35 .053 1.83 .072 2.31 .091 2.31 .091 2.89 .114 2.89 .114 3.58 .141 3.58 .141 4.29 .169 4.29 .169 4.49 .177 4.49 .177 4.60 .181 4.60 .181 5.28 .208 5.28 .208 5.82 .229 5.82 .229 6.02 .237 6.02 .237 6.68 .263 6.68 .263 7.24 .285 7.24 .285 7.47 .294 7.47 .294

6.60 197 .260 73/4 7.49 197 .295 73/4 8.81 229 .347 9 8.76 254 .345 10 8.18 248 .322 93/4 17.75 279 .699 11 11.96 254 .471 10 18.69 305 .736 12 18.77 305 .739 12 25.12 353 .989 137/8 18.77 305 .739 12 27.25 353 1.073 137/8 29.46 302 1.160 117/8 29.46 406 1.160 16 29.11 295 1.146 115/8 33.04 400 1.301 153/4 35.46 305 1.396 12 38.35 508 1.510 20 35.26 305 1.388 12 39.85 513 1.569 203/16 40.94 302 1.612 117/8 40.31 503 1.587 1913/16 40.39 302 1.590 117/8 40.03 503 1.576 1913/16 36.98 270 1.456 105/8 40.72 508 1.603 20

- 20 - 18 - 16 - 16 - 13 - 13 - 13 - 11 - 11 - 11 - 11 - 10 - 10 - 10

1-8 1-8 1-8 1-8 1-8

2 11/4 - 7 1 11/4 - 7 2 11/4 - 7 1 11/4 - 7 2 11/4 - 7 1 11/2 - 6 2 11/2 - 6

Tolerance - Based on +/-.0005

# Minimum length of part recommended to prevent part from dropping in between broach teeth *Based on mild steel

Specials
We are fully equipped to manufacture Special Pull-Type Keyway Broaches to your specifications. A special chamfering feature that will deburr the keyway while it is being broached is also available. All standard items are available with TiN or TiAIN coatings from stock or short delivery. Please contact factory for details. 15

Square Push Broaches

1/ 8

through 1 inch square

Applications: Drives, jigs, fixtures, and other square broaching operations

Dimensions of Standard Square Broach Holes

Square Push Broaches

duMONT Minute Man Standard Square Broaches are designed to generate in one-pass a Standard Square hole in a previously cast or drilled round hole. Standard Square Broaches begin in an oversized pilot hole and generate the square hole while leaving small radii on the flats. Available from stock in the most common American Standard sizes (1/81"). TiN or TiAIN coatings available.

Stock Standard Square Broaches

EDP No. 66601 66602 66603 66604 66605 66606 66607 66608 66609 66610 66611 66612 66613 66614 66615 66616 66617 66618 66619 Square Size
1/8 5/32 3/16 7/32 1/4 9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2 9/16 5/8 11/16 3/4 7/8

Tolerances .1255 - .1265 .1565 - .1575 .1880 - .1890 .2190 - .2200 .2505 - .2515 .2815 - .2825 .3130 - .3140 .3440 - .3450 .3755 - .3765 .4065 - .4075 .4380 - .4390 .4690 - .4700 .5005 - .5015 .5630 - .5640 .6260 - .6270 .6885 - .6895 .7510 - .7520 .8765 - .8775 1.002 - 1.0030

Broach Length 41/8 51/8 59/16 63/8 61/2 73/4 77/8 93/8 93/8 105/8 107/8 12 12 143/4 165/16 173/4 173/4 223/4 241/8

Pilot Diameter .1285 .1590 .1935 .2280 .2656 .2969 .3281 .3594 .3906 .4219 .4531 .5000 .5312 .5938 .6562 .7500 .8125 .9375 1.0938

Drill Size No. 30 No. 21 No. 10 No. 1 17/64 19/64

21/64 23/64 25/64 27/64 29/64 1/2 17/32 19/32 21/32 3/4 13/16 15/16

Dimension Across Corners .1750 - .1770 .2180 - .2200 .2620 - .2640 .3060 - .3080 .3510 - .3530 .3930 - .3950 .4370 - .4390 .4830 - .4850 .5240 - .5260 .5690 - .5710 .6110 - .6130 .6570 - .6590 .6990 - .7010 .7870 - .7890 .8730 - .8750 .9630 - .9650 1.0450 - 1.0470 1.2270 - 1.2290 1.4030 - 1.4050

Tooth Pitch
1/8 5/32 5/32 3/16 3/16 7/32 7/32 1/4 1/4 9/32 5/16 5/16 5/16 3/8 7/16 7/16 7/16 7/16 7/16

Length of Cut* Min. & Max.

3/16 1/4 1/4 1/4 1/4 5/16 3/8 3/8 3/8 1/2 1/2 1/2 1/2 1/2 5/8 5/8 5/8 5/8 5/8 1/2 1/2 5/8 3/4 3/4

Pressure Reqd.for Max.L/C* 700 lbs. 600 1080 1410 1740 2130 2100 3480 3720 4080 4500 4000 4500 5700 5920 4800 5940 9200 9200

1 1 11/4 11/4 13/8 13/8 13/8 13/8 11/2 15/8 15/8 15/8 2 2

13/32

Tolerances-Basic minus .0005-.001 inches *Based on mild steel

Specials
We are fully equipped to manufacture Special Square Broaches not listed above to your specifications. All standard items are available with TiN or TiAIN coatings from stock or short delivery. Please contact factory for details.

16

Full Square Push Broaches

3/ 16

through 1/2 inch full square

Round Push Broaches

1/ 4

through 1 inch round

Applications: Drives, jigs, and fixtures Sizing and finishing Dimensions of Full Square Broach Holes

Full Square Broaches

duMONT Minute Man Full Square Broaches are designed to generate in one-pass a Full Square hole in a previously cast or drilled round hole. The Broach leaves no radii on the flats of the broached piece and the pilot diameter equals the finished full square size. TiN or TiAIN coatings available.

Stock Full Square Broaches

EDP No. 66403 66405 66407 66409 66411 66413 Full Square Size
3/16 1/4 5/16 3/8 7/16 1/2

Tolerances (Dec. Equiv.) .1880 - .1890 .2505 - .2515 .3130 - .3140 .3755 - .3765 .4385 - .4395 .5005 - .5015

Broach Length 6 81/2 101/2 131/8 141/4 143/4

Pilot Diameter
3/16 1/4 5/16 3/8 7/16 1/2

Drill Size
3/16 1/4 5/16 3/8 7/16 1/2

Dimension Across Corners .2630 - .2650 .3510 - .3530 .4390 - .4410 .5260 - .5280 .6140 - .6160 .7010 - .7030

Tooth Pitch
1/8 5/32 3/16 7/32 7/32 1/4

Pressure Length of Cut* Reqd.for Min. & Max. Max. LOC*

3/16 1/4 5/16 5/16 5/16 3/8 1/2 5/8 7/8

870 lbs. 1310 1895 2410 3090 3860

1 1 1

Tolerances-Basic minus .0005-.001 inches *Based on mild steel

Round Broaches
duMONT Minute Man Round Broaches are designed to generate in one-pass a precision round hole in a previously cast, drilled or reamed round hole. These Internal Hole Broaches are ideal for precise tolerances, sizing and finish for those applications demanding precision and finish. Broaches are finished with variable pitch teeth and available in American Standard sizes (1/41"). A burnishing section can be furnished. Metric sizes available upon request. TiN or TiAIN coatings available.

Stock Round Broaches

EDP No. 77730 77731 77732 77733 77734 77736 77738 77740 77742 Nominal Diameter
1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8

Tolerances .2505 - .2510 .3130 - .3135 .3755 - .3760 .4380 - .4385 .5005 - .5010 .6255 - .6260 .7505 - .7510 .8755 - .8765 1.0005 - 1.0015

Broach Length 57/8 57/8 67/8 67/8 8 81/2 91/8 91/4 101/4

Pilot Diameter .2344 .2469 .3594 .4219 .4844 .6094 .7344 .8594 .9844

Drill Size
15/64 19/64 23/64 27/64 31/64 39/64 47/64 55/64 63/64

Length of Cut* Min. & Max.

5/16 5/16 3/8 3/8 1/2 1/2 5/8 5/8 5/8 3/4 3/4

Pressure Reqd. for Max. L/C* 840 lbs. 1050 1440 1680 2240 2500 3720 4340 4970

1 1 11/4 11/4 11/2 11/2 13/4

Tolerance-Basic minus .0005-.001 inches for standard drilled hole *Based on mild steel

Specials
We are fully equipped to manufacture Special Full Square Broaches and Special Round Broaches not listed above to your specifications. All standard items are available with TiN or TiAIN coatings from stock or short delivery. Please contact factory for details.

17

Hexagon Push Broaches

1/ 8

through 1 inch hex sizes

Applications: Drives, jigs, fixtures, and other hexagonal broaching operations

Dimensions of Standard Hexagon Broach Holes

Hexagon Broaches
duMONT Minute Man Hexagon Broaches are designed to generate in one-pass a Hexagon hole in a previously cast or drilled round hole. Available from stock in the most common American Standard sizes (1/81"). TiN or TiAIN coatings available.

Stock Hexagon Broaches

EDP No. 77701 77702 77703 77704 77705 77706 77707 77708 77709 77710 77711 77712 77713 77714 77715 77716 77717 77718 77719 Hex Size
1/8 5/32 3/16 7/32 1/4 9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2 9/16 5/8 11/16 3/4 7/8

Tolerances .1255 - .1265 .1565 - .1575 .1880 - .1890 .2190 - .2200 .2505 - .2515 .2815 - .2825 .3130 - .3140 .3440 - .3450 .3755 - .3765 .4065 - .4075 .4380 - .4390 .4690 - .4700 .5005 - .5015 .5630 - .5640 .6260 - .6270 .6885 - .6895 .7510 - .7520 .8765 - .8775 1.0020 - 1.0030

Broach Length 41/8 415/16 51/16 53/8 6 71/4 73/4 73/4 81/2 95/8 101/2 117/8 117/8 133/4 161/4 163/4 171/4 181/2 193/4

Pilot Diameter
1/8 5/32 3/16 7/32 1/4 9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2 9/16 5/8 11/16 3/4 7/8

Drill Size
1/8 5/32 3/16 7/32 1/4 9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2 9/16 5/8 11/16 3/4 7/8

Dimension Across Corners .1445 - .1455 .1800 - .1815 .2160 - .2180 .2500 - .2520 .2870 - .2890 .3230 - .3250 .3590 - .3610 .3950 - .3970 .4310 - .4330 .4670 - .4690 .5040 - .5060 .5390 - .5410 .5750 - .5770 .6480 - .6500 .7200 - .7220 .7920 - .7940 .8650 - .8670 1.0080 - 1.0100 1.1520 - 1.1540

Tooth Pitch
1/8 1/8 5/32 5/32 3/16 3/16 7/32 7/32 7/32 1/4 1/4 9/32 9/32 5/16 3/8 3/8 3/8 3/8 3/8

Pressure Length of Cut* Reqd. for Min. & Max. Max. L/C*
3/16 1/4 1/4 1/4 1/4 5/16 3/8 3/8 3/8 1/2 1/2 1/2 1/2 1/2 5/8 5/8 5/8 5/8 5/8 3/8 1/2 5/8 3/4 3/4

200 lbs. 300 560 775 1025 1290 1510 2280 2400 2790 2700 2700 3025 4800 5400 6000 6960 8400 11100

1 1 11/4 11/4 13/8 13/8 13/8 13/8 15/8 2 2 2 2 2

Tolerances-Basic minus .0005-.001 inches *Based on mild steel

Specials
We are fully equipped to manufacture Special Hexagon Broaches not listed above. All standard items are available with TiN or TiAIN coatings from stock or short delivery. Please contact factory for details.

18

Metric Square
4mm through 25mm square (I.S.O.)

Hexagon Broaches
4mm through 25mm hex (I.S.O.)

Applications: Metric drives, jigs, fixtures, and other square and hexagonal broaching operations

Stock Metric Standard Square Broaches

EDP No. 66630 66631 66632 66633 66634 66639 66635 66636 66637 66638 66640 66641 66642 66643 66644 Square Size mm 4 5 6 7 8 9 10 12 14 16 18 20 22 24 25 Tolerances (Dec. Equiv.) .1575 - .1580 .1968 - .1973 .2362 - .2370 .2756 - .2764 .3150 - .3158 3543 - .3551 .3937 - .3945 .4724 - .4732 .5512 - .5520 .6302 - .6310 .7090 - .7097 .7874 - .7882 .8663 - .8671 .9453 - .9460 .9845 - .9852 Broach Length 51/8 61/2 611/16 73/4 77/8 93/8 101/4 12 143/4 165/16 177/8 207/8 223/4 24 241/8 Pilot Diameter .1614 .2047 .2519 .2913 .3307 .3701 .4094 .5039 .5826 .6614 .7716 .8504 .9291 1.0079 1.0630 Drill Size mm 4,1 5,2 6,4 7,4 8,4 9,4 10,4 12,8 14,8 16,8 19,6 21,6 23,6 25,6 27,0 Dimension Across Corners .2205 - .2220 .2765 - .2780 .3300 - .3320 .3850 - .3870 .4400 - .4420 .4970 - .4990 .5530 - .5550 .6620 - .6640 .7730 - .7750 .8790 - .8810 .9930 - .9950 1.1030 - 1.1050 1.2130 - 1.2150 1.3230 - 1.3250 1.3790 - 1.3810

TiN or TiAIN coatings available. Pressure Length of Cut* Reqd. for Min. & Max. Max.L/C*
1/4 1/4 1/4 3/8 3/8 3/8 3/8 1/2 1/2 5/8 5/8 5/8 5/8 5/8 5/8 1/2 1/2 3/4

Tooth Pitch
5/32 5/32 3/16 7/32 7/32 1/4 1/4 5/16 3/8 7/16 7/16 7/16 7/16 7/16 7/16

480 lbs. 800 1300 1800 2300 3500 3600 4200 5600 6000 5200 6600 8900 9200 9200

1 1 11/4 11/4 13/8 11/2 15/8 15/8 15/8 2 2 2

Tolerances-Basic minus .0005-.001 inches *Based on mild steel Refer to the diagram on page 16 for dimensions of standard Square Broach holes

Stock Metric Hexagon Broaches

EDP No. 77750 77751 77752 77753 77754 77759 77755 77756 77757 77758 77760 77761 77762 77763 77764 Hexagon Size mm 4 5 6 7 8 9 10 12 14 16 18 20 22 24 25 Tolerances (Dec. Equiv.) .1575 - .1580 .1968 - .1973 .2362 - .2370 .2756 - .2764 .3150 - .3158 .3545 - .3555 .3937 - .3945 .4724 - .4732 .5512 - .5520 .6302 - .6310 .7092 - .7097 .7876 - .7886 .8664 - .8674 .9450 - .9460 .9845 - .9855 Broach Length 415/16 53/8 6 71/4 73/4 81/2 95/8 117/8 133/4 161/4 163/4 175/8 181/2 191/2 193/4 Pilot Diameter .1575 .1968 .2362 .2756 .3150 .3543 .3937 .4724 .5512 .6299 .7087 .7874 .8661 .9449 .9842 Drill Size mm 4,0 5,0 6,0 7,0 8,0 9,0 10,0 12,0 14,0 16,0 18,0 20,0 22,0 24,0 25,0 Dimension Across Corners .1810 - .1825 .2260 - .2275 .2710 - .2730 .3170 - .3190 .3620 - .3640 .4090 - .4110 .4530 - .4550 .5430 - .5450 .6350 - .6370 .7250 - .7270 .8170 - .8190 .9050 - .9070 .9990 - 1.0010 1.0890 - 1.0910 1.1350 - 1.1370

TiN or TiAIN coatings available. Pressure Length of Cut* Reqd. for Min. & Max. Max. L/C*
1/4 1/4 1/4 1/4 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 5/8 5/8 1/2 3/4 3/4

Tooth Pitch
1/8 5/32 3/16 3/16 7/32 7/32 1/4 9/32 5/16 3/8 3/8 3/8 3/8 3/8 3/8

300 lbs. 775 1025 1290 1510 2300 2790 2700 4800 5400 6400 7200 8200 9700 11000

1 1 11/4 13/8 13/8 15/8 2 2 2 2 2 2

Tolerances-Basic minus .0005-.001 inches

*Based on mild steel

Refer to the diagram on page 18 for dimensions of Hexagonal Broach holes

Specials
We are fully equipped to manufacture Special Metric Square and Hexagon Broaches not listed above. All standard items are available with TiN or TiAIN coatings from stock or short delivery. Please contact factory for details.

19

Special Broaches
Push and Pull Types

Applications: Virtually any broaching operation Short and long-run production

Capabilities
The duMONT Company, LLC, is a leading specialist in the design and manufacture of Broaches for industrial applications. Along with the extensive assortment of Stock Broaches listed in this catalog, we offer rapid delivery of Special Broaches customdesigned for your application or manufactured from your prints. We are fully equipped to manufacture both Standard and Special Broaches in either Push or Pull Styles, including all types of Keyway, Internal Hole, and Surface Broaches. Special features, such as chamfering or deburring for one-pass operation are readily available. All duMONT Special Broaches are manufactured of the highest quality high-speed steel. duMONTs engineering staff has years of experience designing Special Broaches to replace time-consuming and costly machining operations. Whenever possible we will meet your Special Broach requirements by modifying an existing Stock Broach, thereby reducing both the cost and delivery time ordinarily associated with ordering Specials. With our extensive stock and expertise in designing and manufacturing specials, we are able to serve our customers as a single complete source for all of their broaching needs.

TiN or TiAIN Coating Available.

20

Special Broaches
Push and Pull Types

Applications: Virtually any broaching operation Short and long-run production

Keyway Broaches
duMONT manufactures Special Keyway Broaches in either Push or Pull Type in both American Standard and Metric Sizes. Special Application Multi-pass Push Keyway Broaches, and One-Pass Keyway Broaches which require the appropriate guide Bushing can often be manufactured from an existing blank for quick delivery. One-Pass Push Keyway Broaches are also available in a self-guiding Production Style that require no guide Bushing. Both One-Pass Push-Type styles as well as their PullType counterparts are available with a special chamfer feature that will deburr the keyway bore interface. Double-Keyway and Keyseating Broaches are also available. Pull-Type Broaches are available with a variety of pull ends Threaded, Notched, Pin, and Automatic to name a few.

Spline Broaches
Spline Broaches specifically designed and manufactured for your application, duMONT offers straight sided, Involute Spline, and Serration Broaches in both Push or Pull-Type designs. Due to the complex nature of these tools a customer part print is required. Pull-Type Broaches are available with a variety of pull ends Threaded, Notched, Pin, and Automatic to name a few.

Let Us Meet Your Special Broach Requirements

duMONT Special Broaches can be ordered from your industrial distributor. Check to see if a standard item will serve your needs, before ordering a Special Broach. Using standard items means off-the-shelf delivery and substantially lower cost. When standard items are not appropriate, we would be pleased to design and manufacture a Broach to meet your specific needs. What We Need To Know A fully dimensioned drawing of the finished part, casting, forging, or broach would be most helpful. When a part print is unavailable, the following information should be provided:

Surface Broaches
Surface Broaches are available as either individual Broaches or as inserts for broaching flat surfaces, irregular shapes, external forms, concave or convex surfaces, serrations, cam shaped, corner squaring, and dovetails.

1. Description of Cut (Size/Shape/Tolerance) 2. Length of Cut 3. Type of Material to be Broached 4. Size and Shape of Hole or Surface to be Broached (For cast holes, give minimum hole size, including draft and fillet radii, if any) 5. For Keyway Broaches Give: a. Minimum Bore Size b. Depth of Keyway Across Bore c. Width of Keyway d. Tolerance

Internal Hole Broaches

Internal Hole Broaches in Push and Pull-Type including Square, Hexagon, Round, D-Hole, Double-D, Rectangular, Inverted Keyway, and irregularly shaped Broaches are all readily available. Broaches for Burnishing, Sizing and Combination or Cut and Finish applications are also manufactured as either Push or Pull-Type. Pull-Type Broaches are available with a variety of pull ends Threaded, Notched, Pin, and Automatic to name a few.

6. Type of Broaching Machine (Push or Pull/Tonnage/Ram Travel/Daylight Opening) 7. Number of Pieces to Broach

21

Engineering Section
How to Use Minute Man Broaches

Standard Push Broaching Procedures Broaching Basics

Standard Broaching Procedures

duMONT Minute Man Broaches are designed for fast, accurate, and convenient broaching with arbor or hydraulic presses. A study of the Broaching Procedures presented in this section will familiarize the operator with proper broaching procedures and troubleshooting practices. Following proper broaching fundamentals, paying attention to technique and Broach maintenance will help prevent drifting, deflection and even breakage while providing greater efficiencies in the cutting of your parts. If you have a specific question or problem, contact our Engineering Department at 413-773-3674 / 800-628-9648 or by email at info@dumont.com.

being used. Reminder: A Style Broaches are used with A Style Bushings, B Style Broaches with B Style Bushings, etc. duMONT Minute Man Special Push-Type and Pull-Type Broaches often can be designed to accommodate your specific length of cut requirements. Set-Up & Alignment Successful broaching begins with proper Set-up, and Alignment of the Broach, workpiece and ram. Attention to these details will provide a stable workpiece, and prevent drifting, deflection or even breakage caused by misalignment. The workpiece must be solidly fixed or nested perfectly square with the baseplate and ram face. Make sure all square and parallel surfaces on the face of the ram and baseplate remain true. It is essential to maintain a rigid set-up at all times and caution should be taken when stacking parts to maintain the integrity of the set-up. Never attempt to exceed the Broachs specified Maximum Length of Cut. At the beginning of a cut, be sure the Broach is centered under the ram. Proper alignment is important. After the Broach starts to cut, back off pressure on the ram to allow the Broach to center itself, if not in perfect alignment. If Broach moves out of alignment after starting cut, back off the pressure on the ram and align the broach itself. Repeat this procedure during successive cuts. This will assure a perfectly straight broached hole. Suggestions for a drifting or hogging Push-Type Keyway Broach: 1. Reverse workpiece or turn Broach so teeth face toward the back of the press. 2. Let the Bushing protrude above the workpiece to give more support to the back of the Broach, thereby helping to keep it aligned. If a collared Bushing is used, place it upside down under the workpiece. Ram Adapter Use

Broaching Basics

Warning Information Cutting tools may shatter or break, therefore eye protection should be worn wherever and whenever cutting tools are being used. Government Regulations require use of safety glasses and other appropriate safety equipment at all times in the vicinity of cutting tool use. Workpiece Material duMONT Minute Man stock Broaches can be used on a variety of workpiece materials, it is not practical to Broach material having a Rockwell hardness higher than Rc35. When broaching Iron or Steel use the standard Broach as supplied. Brass and Free Machining Bronze may require stoning of a slight land on the top of the teeth to prevent drifting (pulling into the work). Special Broaches are designed and engineered to provide the correct tooth form, pitch and rake angles for the material specified. Length of Cut duMONT Minute Man Broaches are designed to be used in operations where a minimum of two teeth are engaged at all times. Tooth engagement is required to maintain a smooth cutting action promoting a clean finish. The chip generated during the cutting process must be contained within the gullet of the tooth to avoid binding of the tool. This could cause potential damage to the Broach, the workpiece and injury to the operator. Appropriate chip load allows for smooth cutting, and improved tool life. All individual stock Broaches have recommended Minimum and Maximum Length of Cut guidelines which should be followed. The required force necessary to achieve the Maximum Length of Cut is also provided with the individual Broach specifications. Workpieces may be stacked to establish the Minimum Length of Cut, or to improve the efficiencies of the operation as long as Maximum Length of Cut is not exceeded. Proper nesting and clamping of stacked parts is vital when this approach is taken. The Maximum Length of Cut with Push-Type Keyway Broaches should not exceed the length of the Bushing

Ram Adapters are used for broaching applications that require Round, Special Shapes such as Oval, D-Holes and Rectangular as well as Square, and Hexagon Broaches 1/4 and 6mm or smaller. A Ram Adapter would also be recommended in situations where an extraordinary high degree of accuracy is required. These Adapters are also referred to as rear guides and provide support and guidance for the Broach at the shank end, minimizing the possibility of deflection or breakage. When an

22

Engineering Section
How to Use Minute Man Broaches
Adapter is used as a rear guide for the Broach, the hole in the Ram Adapter must be in alignment with the pilot hole in the workpiece. It is important a Ram Adapter provides a tight, true fit to both the press ram and to the Broach shank. An adapter may also be used to allow the shanks of smaller Internal Hole Broaches to be gripped to avoid deflection and breakage. Cutting Fluids & Lubrication Broach lubrication is crucial to tool life and the quality of the finish produced. Lubrication enables chips to slide freely and curl in the tooth gullets minimizing frictional heat. This cuts down on Broach wear and prevents build up on the cutting edge of the teeth. Push-Type Keyway Broaches, regardless of the material to be broached, require lubrication on the back side of the Broach in order to reduce friction. Proper lubrication will increase Broach life and produce a cleaner finish. Various materials require different lubricants. duMONT Minute Man recommends the following: Mild Steel A good quality cutting oil or water soluble coolant brushed on the teeth and back side of the Broach. Tough Steels such as Nickel Alloys A good grade of a sulfur based cutting oil. Brass Typically is broached dry. Bronze Works well with an oil or soluble oil. Cast Iron Is almost always broached dry but requires lubrication for the backside of the Broach. Aluminum Straight Kerosene may be used but special lubricants are available. You may wish to contact your cutting fluid dealer for additional recommendations and availability. Coatings Available duMONT Minute Man Broaches are available with TiN, and TiAlN coatings. The coatings provide enhanced performance for specific applications, delivering greater value and tool life on your more challenging materials. . TiN provides increased lubricity and wear resistance when broaching abrasive materials such as Fiberglass and some Aluminum Alloys. TiAlN offers significant increase in surface hardness (Rc low 90s). Applications would include broaching in most Stainless Steels, Alloy Steels, and harder materials.

Standard Push Broaching Procedures Broach Re-sharpening

Nicks, gouges, etc. in the teeth from improper handling. Broach sticking in the workpiece, pick-up on tops of teeth. Holes gauging undersize. duMONT Minute Man offers expert Broach re-sharpening services, with the goal to restore the cutting edges of the Broach to its original condition. Broaches returned for this service are each individually examined and specific regrind instructions are generated for the reconditioning of the tool. Broaches exhibiting excessive wear are evaluated to insure a re-sharpening is appropriate or if it is time to consider replacing the tool. The re-sharpening process is a precision operation, under or over sharpening will produce unsatisfactory results. Removing too much material in the re-sharpening process can dramatically reduce tool life. Improper re-sharpening can result in a departure from original tooth form, creating under sized parts, compromised cutting action and potentially causing irreparable damage. Correct sharpening ensures satisfactory production in terms of time efficiency, conformance to specifications and finish. duMONT Minute Man is fully equipped to provide expert re-sharpening services. We need to evaluate the Broach, to insure it is able to be adequately reconditioned. Based on this examination a quote for re-sharpening would be provided.

Broaching with Keyway Sets or Individual Broaches

Use of Individual Push-Type Keyway Broaches or Keyway Broaches from a Broach Set requires the use of a Bushing and Shim(s). The Bushing size and Style are determined by the bore diameter of the workpiece as well as the Style of Broach to be used. A Style Broaches are used with A Style Bushings, B Style Broaches with B Style Bushings, etc. The smallest Broaches cut in one pass and require no Shim. Multiple pass Keyway Broaches are furnished with all necessary Shim(s) unless otherwise noted. A Shim is required to compensate for the thickness removed following a Keyway Broachs cutting pass. The addition of a Shim to the bottom of the bushings slot serves to move the Broach forward towards its standard finished cutting depth. Subsequent passes require the stacking of Shims. 1. Select the right Bushing for the bore (sizes are plainly marked) and insert in the bore of work. 2. Insert Broach (which is also plainly marked for size) into the Bushing slot and check alignment. 3. Place this assembly in the press. 4. Lubricate.

Broach Re-sharpening
Broaches, regardless of type, should never be used when dull. The use of a dull Broach may result in poor finish or cause drifting, damage to the teeth or breakage. Correct and timely re-sharpening will increase Broach life and quality of parts. The necessity to sharpen a Broach is dependent on numerous factors; material, tolerance, and required finish, etc. A number of conditions indicate the need for sharpening: Poor finish, tears, galling, etc. on the workpiece. Cutting edges showing signs of rollover and teeth dull to the touch. When using a Hydraulic Press, the pressure gage showing an increase in pressure required to complete the cut.

23

Engineering Section
How to Use Minute Man Broaches
5. Apply pressure to the Broach back off pressure on Ram to allow the Broach to center itself if not in perfect alignment reapply pressure to push Broach through the work. 6. Clean Broach using a stiff brush to remove chips from cutting section. 7. Insert Shim and repeat steps 3 thru 6 as required to obtain exact keyway depth.

Standard Push Broaching Procedures Troubleshooting

Broaching with Internal Hole Broaches

Broaching with Internal Hole Broaches requires no Shims or Bushings. Round, Square, Hexagon and many Special Shapes are designed to finish in one pass, in cast or drilled bores requiring a through hole finish. The starting hole must be drilled square with the face of the work. Square and Hexagon Broaches, 1/4" and 6mm or smaller, should be gripped by the shank in an adapter to prevent deflection and breakage. 1. Pilot Holes: Properly drilled pilot holes are essential for a true and clean cut. Never use a dull or poorly sharpened drill to make pilot holes. 2. Select desired Broach. Confirm the bore of workpiece is equal to pilot diameter of broach. (The use of a ram adapter is advised with all Round, Oval, D-hole Broaches, and for Square and Hexagon Broaches 1/4" and 6mm or smaller). 3. Insert pilot into bore of part. 4. Ram Speed: Always use proper ram speed to prevent chatter marks and edge wear. (See Metals Handbook Vol. 3 Machining.) 5. Lubricate. 6. Apply pressure to the Broach back off pressure on Ram to allow the Broach to center itself, if not in perfect alignment reapply pressure to push Broach through the work. 7. Clean Broach using a stiff brush to remove chips from cutting section. 8. Repeat steps 3 thru 7 for subsequent parts.

Broaching with One-Pass Keyway Broaches

Broaching with One-Pass Keyway Broaches requires the use of a Bushing. The Bushing size and Style are determined by the bore diameter of the workpiece as well as the Style of Broach to be used. A Style Broaches are used with A Style Bushings, B Style Broaches with B Style Bushings, etc. No Shims are required. The Broach cuts to full width and depth in one pass. 1. Select the right Bushing for the bore (sizes are plainly marked) and insert in the bore of work. 2. Insert Broach (which is also plainly marked for size) for the desired width of keyway into the Bushing slot and check alignment. 3. Place this assembly in the press. 4. Lubricate. 5. Apply pressure to the Broach back off pressure on Ram to allow the Broach to center itself, if not in perfect alignment reapply pressure to push Broach through the work. 6. Clean Broach using a stiff brush to remove chips from cutting section. 7. Repeat steps 2 thru 6 for subsequent parts.

Troubleshooting
duMONT Minute Man aims to make your broaching experience efficient, effective and trouble free. Most broaching failures (poor finish, drifting, deflection, breakage, chatter marks, or edge wear) can be attributed to deficiencies in alignment, lubrication, Broach sharpness, tooth configuration or design, material hardness, and incorrect broaching speed or pressure as detailed in this section. If you have specific questions or problems not covered on these pages, contact our Engineering Department.

Broaching with Production Keyway Broaches

Broaching with Production Style Keyway Broaches requires no Shims or Bushings. The back and shoulders of the Broach are ground to fit the diameter of the bore, supporting and guiding itself while cutting the keyway in one pass 1. Select desired Broach and insert pilot into bore of part. 2. Lubricate. 3. Apply pressure to the Broach back off pressure on Ram to allow the Broach to center itself, if not in perfect alignment reapply pressure to push Broach through the work. 4. Clean Broach using a stiff brush to remove chips from cutting section. 5. Repeat steps 2 thru 4 for subsequent parts.

The duMONT Company, LLC

289 WELLS STREET, PO BOX 469 GREENFIELD, MA 01302 USA TEL. 413-773-3674 or 800-628-9648 FAX 413-773-8430 or 800-331-9957 E-MAIL: info@dumont.com www.dumont.com
MADE in the USA

24

duMONT Arbor Presses

3 and 5 Ton Models Arbor Presses
duMONT Minute Man Arbor Presses are easy to operate Manual Broaching Machines designed for Push Broaching with Keyways and Internal Hole Broaches. These Hand Operated Presses are available in 3 and 5 Ton Models and provide the pressure required to Push Broaches through the work piece. Both Arbor Presses provide these essential features: Ratchet operation with compound leverage for minimum operator effort. Pawl between lever and pinion permits positioning lever for most convenient reach and pull. Counter weight returns lever to upright rest position. Ram positioned by handwheel reduces travel, tests Broach alignment, supports the Broach and workpiece assembly. Round ram with rack teeth cut to center concentrates force along the center line to avoid cramping. Rugged table machined square with ram, and slotted for Broach drop-through. Please contact factory for details.

Applications: Easy-to-operate manual broaching machines for use with most duMONT Broaches

Arbor Press Specifications

EDP No. 88810 88811 88812 88813 Press Size No. 2-R No. 3-R Takes Diameters Up To 12" 21" Height Over Plate 171/4" 201/2" Height Overall 32" 35" 22" x 19" x 32" 26" x 20" x 32" Takes Broaches A-B-B1-C A-B-B1-C-D Shipping Weight 220 lbs. 517 85 117

Leverage 45-1 55-1

Pressure 3 ton 5 ton

STAND for No. 2-R Press STAND for No. 3-R Press

Warranty
The duMONT Company, LLC, warrants to original equipment manufacturers, distributors and industrial and commercial users of its products that each new product manufactured or supplied by The duMONT Company, LLC, shall be free from defects in material and workmanship. The duMONT Company, LLC, obligation under this warranty is limited to furnishing without additional charge a replacement or, at its option, repairing or issuing credit for any product which shall within one year from the date of sale be returned freight prepaid to the plant designated by The duMONT Company, LLC, representative and which upon inspection is determined by The duMONT Company, LLC, to be defective in materials or workmanship. Complete information as to operating conditions, machine setup, and application of cutting fluid should accompany any product returned for inspection. The provisions of this warranty shall not apply to any duMONT Company, LLC, product which has been subjected to misuse, improper operating conditions, machine setup or application of cutting fluid or which has been repaired or altered if such repair or alteration in the judgment of The duMONT Company, LLC, would adversely affect performance of the product. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The duMONT Company, LLC, shall have no liability or responsibility on any claim of any kind, whether in contract, tort or otherwise, for any loss or damage arising out of, connected with, or resulting from the manufacture, sale, delivery or use of any product sold hereunder, in excess of the cost of replacement or repair as provided herein. IN NO EVENT SHALL The duMONT Company, LLC, BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES. The duMONT Company, LLC, makes no other warranty, expressed or implied, except as set forth above; and The duMONT Company, LLC, neither assumes nor authorizes any other person or entity to assume for it any other obligation or liability in connection with any of its products.

Warning
Cutting tools may shatter or break, therefore eye protection should be worn wherever and whenever cutting tools are being used. Government Regulations require use of safety glasses and other appropriate safety equipment at all times in the vicinity of cutting tool use.

25