How to Choose the Right Broach Tool

1. Understand Your Application

The first step in selecting a broach tool is understanding what the operation requires. Is the profile internal or external? What are the dimensional tolerances and surface finish expectations? Broaching is ideal for producing complex profiles with tight tolerances, but the tool design must match the material hardness, chip space, and length of cut.

2. Choose the Right Material

Most high-performance broaches are manufactured from High Speed Steel (HSS) or Powder Metallurgy HSS (PM-HSS). For short production runs or soft materials, M2 or M35 HSS is often sufficient. For harder steels and large-volume production, PM-HSS such as ASP 2030 or 2060 offers superior wear resistance and toughness. Carbide-tipped broaches are occasionally used for nonferrous materials or very high production volumes.

3. Geometry and Tooth Design

The geometry of a broach defines its performance. The main parameters include:

• Rake Angle: affects chip formation and cutting forces. 10°–15° for soft steels, 0°–5° for hard steels.
• Relief Angle: prevents rubbing; typically 2°–6° depending on profile depth.
• Tooth Pitch (P): the spacing between cutting teeth; smaller for fine finishes, larger for aggressive roughing.
• Rise per Tooth (RPT): determines chip thickness and load; 0.01–0.05 mm for finish, 0.05–0.15 mm for roughing.

4. Broach Length and Staging

A well-designed broach has three zones: roughing, semi-finishing, and finishing. The roughing teeth remove most material, semi-finish corrects geometry, and finishing achieves final tolerance and surface quality. Each stage must balance cutting load to avoid vibration or deflection, especially for long tools over 1200 mm.

5. Coating and Surface Treatment

PVD coatings such as TiN, TiAlN, AlCrN significantly improve tool life and reduce friction. The correct coating depends on material and cooling strategy. For example, TiAlN excels at dry or high-speed broaching; TiN offers excellent adhesion and economy for general use.

6. Inspection and Quality Assurance

Each broach should be inspected with Go/No-Go gauges and verified on CMM (Coordinate Measuring Machine) before dispatch. Dimensional control is especially critical for spline and serration profiles following standards like DIN 5480, ISO 4156, or ANSI B92.1.

7. Partner with an Experienced Manufacturer

A precise broach is not only about geometry—it’s about expertise in heat treatment, grinding, and profile control. Choosing a specialized manufacturer ensures consistent performance, fast re-sharpening service, and long-term reliability.

Need help selecting your next broach?
Contact our engineers at Broş Takım Sanayi for professional guidance and quotation.