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Home > Double D Rotary Broach

Double D Rotary Broach

Double D Rotary Broach Special Form

Shaft End Broaching

Double D Rotary BroachDesigning forms at the end of a shaft is a common solution for locking the shaft in place or aligning it to other features of the mechanical device. If a single flat is desired, the flat can milled or machined in a variety of ways. However, machining flats in the connecting pieces can sometimes be a challenge. If the major diameter of the form is smaller than one inch, rotary broaching may be a solution.

To begin, check the size of the form. For example, with a double flat design, also known as double-D or DD, divide the difference of the flat-to-flat dimension and the major diameter in half. This will give you the broaching ‘height’. The ideal broaching height is less than .035” in soft metals, and even lower in steel. The depth of the form should not exceed one and a half times the flat-to-flat dimension, although Polygon Solutions’ broaches are designed to broach two times that diameter if possible.

Next select the broach shank size. Rotary broaches are available in 8mm and half inch shanks. The Polygon Solutions rotary broach tool holder can be order with 8mm or half-inch bore for the size broach desired. Standard broaches from Polygon Solutions also include a pressure relief hole, to allow fluid and air to escape when broaching blind holes.

The pilot hole for this form should be at least the flat-to-flat dimension or larger. The larger the hole, the smaller the amount of pressure required for the machining operation. Additionally, the hole should be chamfered. The major diameter of the chamfer should be at least the major diameter of the form.

To receive a quote on a Double D Rotary Broach Form please fax your drawing or dimensions to 239-628-4801 or call 239-628-4800.  You may also email us your print through our Request Quote Form.

Special Double-D Forms can usually be shipped within 5 business days.

Special Rotary Broach Features Include:
  • High Quality M2 High Speed Steel
  • Air Vent Hole for Pressure Relief
  • Hardened to over 62 Rockwell
  • Precision Ground Shank

All  rotary broach tools can be ordered with the following custom features:

  • PM M-4, M-42 or PM T-15 High Speed Steel
  • No Air Vent Hole or Double Air Vent Holes
  • Custom Flat-to-Flat Dimensions
  • Coatings:
    • Titanium Nitride
    • Titanium Carbo-Nitride
    • Titanium Aluminum Nitride
  • Custom Form Depth
  • Custom Overall Length

Rotary Broaching Tool Holder

SW Regional Manufacturers Association of Florida


16770 Link Court, Suite #106
Fort Myers, Florida 33912
239-628-4800 | fax 239-628-4801
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