Do you need to make a precision hexagon (hex) form in the end of a metal shaft or fastener?
Of the many ways to accomplish such a task, rotary broaching is no doubt the most popular, most efficient and most cost effective. Best of all, hexagon rotary broaching tools work on almost all turning machines.
The hexagon is an ideal form for fastener drivers. Multiple points of contact provide driving strength without sacrificing the integrity of the fastener. Many of our customers use hex broaches for manufacturing everything from bone screws to door hardware.
Using the hex broach is not difficult, but a few key points should be kept in mind. Rotary broaching does require the use of a chamfer. The chamfer helps the broach to stay on center, and is also the point where the chip begins to curl up at the face of the broach.
An oversize pilot hole is also an important key for rotary broaching. For hexagons, we recommend a minimum 3% oversize pilot hole, which will leave a small radius in the middle of the flat. This small amount of material is acceptable in the ASME standard for hexagon sockets. Pilot hole diameters closer to the flat-to-flat dimension of the broach can be used, but may affect tool life.
Finally, there must be room for the chips to accumulate in the bottom of the hole. If the pilot hole is a through hole, then generally this is not a concern. However, if it is a blind hole, consideration must be given to provide clearance for chip accumulation inside the hole. Drilling the pilot hole 50% deeper than the broaching depth is a rule of thumb for determining final pilot hole depth.
Polygon Solutions is pleased to provide a wide variety of standard inch and metric hex sizes suitable for rotary broaching. Most broaches are available for immediate delivery from our Fort Myers, FL facility. Polygon also offers fast delivery on custom and special order hex broaches.
Polygon Solutions’ 1/2″ shank hexagon rotary broaches are precision ground with a tolerance of +0/-.0005. Each nominal size conforms to the industry standard – ANSI B18.3 2003. All 1/2″ shank hex rotary broach tools include a pressure relief vent hole that allows air and fluid to freely escape during the rotary broaching process to reduce wear on your machine and extend rotary broach tool life. Click Buy Now button to choose broach steel, coatings and quantity.
Polygon Solutions’ 8mm shank hexagon rotary broaches are precision ground with a tolerance of +0/-.0005. Each nominal size conforms to the industry standard – ANSI B18.3 2003. All 8mm shank hex rotary broach tools include a pressure relief vent hole that allows air and fluid to freely escape during the rotary broaching process to reduce wear on your machine and extend rotary broach tool life. Click Buy Now button to choose broach steel, coatings and quantity.
Polygon Solutions’ 8mm shank x 28mm overall length hexagon rotary broaches are precision ground with a tolerance of +0/-.0005. Each nominal size conforms to the industry standard – ANSI B18.3 2003. All 8mm shank x 28mm overall length hex rotary broach tools include a pressure relief vent hole that allows air and fluid to freely escape during the rotary broaching process to reduce wear on your mac
Hexagon Broach Gages can be used with Polygon’s standard ASME broaches to make sure that the size of the hexagon hole has been machined properly. Unlike rotary broaches, hex broach Gages have no taper. Our Hexagon Gages are held to tight tolerances and can be made to custom shapes and sizes. We also offer external hexagon go / nogo gages.
Polygon’s hex broach Gages are made as GO and NOGO pairs. Each gage is designed to be held by hand and inserted into the hexagon hole. If the NOGO Gage fits, then the hole is too large and the part fails inspection. If the GO Gage fits, then the hole is the right size and the part will pass inspection. If the hole was too small the GO Gage would not have fit inside.
Hex Gages can also help to determine if there is too much twist in the form, a common troubleshooting feature of holes manufactured using the rotary broaching process. Our Hexagon Broach Gages are made of durable hardened M-2 tool steel. All Gages come with handles featuring green caps on the GO Gage side and red caps on the NOGO side.
** GO and NOGO hex Gages can easily be customized. Call us with your dimensions at 239-628-4800. Custom hex Gage delivery requires 2-3 days for manufacturing.
Gage Tolerances Conform to ANSI B18.3
Square Broach gages (or gauges) can be used to make sure that the size of the square hole has been machined properly. Unlike rotary broaches, square broach gages have no taper. Our square gages are held to tight tolerances and can be made to custom shapes and sizes.
Polygon’s square broach gages are made as GO and NOGO pairs. Each gauge is designed to be held by hand and inserted into the square hole. If the NOGO gage fits, then the hole is too large and the part fails inspection. If the GO gage fits, then the hole is the right size and the part will pass inspection. If the hole was too small the GO gage would not have fit inside.
Square Gages can also help to determine if there is too much twist in the form, a common troubleshooting feature of holes manufactured using the rotary broaching process. Our Square Broach gages are made of durable hardened M-2 tool steel. All gages come with handles featuring green caps on the GO gage side and red caps on the NOGO side. Gage Tolerances are +0/-.0002.
Hexalobular Broach gages can be used to make sure that the size of the 6-lobed (hexalobular) hole has been machined properly. Unlike rotary broaches, hexalobular broach gages have no taper. Our gages are held to tight tolerances and can be made to custom shapes and sizes. We also offer internal and external hexalobular Go / NoGo Gages.
Polygon’s broach gages are made as GO and NOGO pairs. Each gage is designed to be held by hand and inserted into the hexalobular (6-lobed) hole. If the NOGO gage fits, then the hole is too large and the part fails inspection. If the GO gage fits, then the hole is the right size and the part will pass inspection. If the hole was too small the GO gage would not have fit inside.
Hexalobular Gages can also help to determine if there is too much twist in the form, a common troubleshooting feature of holes manufactured using the rotary broaching process. Our Hexalobular Broach gages are made of durable hardened M-2 tool steel. All gages come with handles featuring green caps on the GO gage side and red caps on the NOGO side.
Major and Minor Diameters Per ISO 10664 and Include Long Form Certification of Calibration.
| Torx-Type Internal Gage Size | ISO Standard | Part # | ||
| T-03 Gage Set | ISO 10664 | T03G | ||
| T-04 Gage Set | ISO 10664 | T04G | ||
| T-05 Gage Set | ISO 10664 | T05G | ||
| T-06 Gage Set | ISO 10664 | T06G | ||
| T-07 Gage Set | ISO 10664 | T07G | ||
| T-08 Gage Set | ISO 10664 | T08G | ||
| T-09 Gage Set | ISO 10664 | T09G | ||
| T-10 Gage Set | ISO 10664 | T10G | ||
| T-15 Gage Set | ISO 10664 | T15G | ||
| T-20 Gage Set | ISO 10664 | T20G | ||
| T-25 Gage Set | ISO 10664 | T25G | ||
| T-27 Gage Set | ISO 10664 | T27G | ||
| T-30 Gage Set | ISO 10664 | T30G | ||
| T-40 Gage Set | ISO 10664 | T40G | ||
| T-45 Gage Set | ISO 10664 | T45G | ||
| T-50 Gage Set | ISO 10664 | T50G |
Polygon Solutions’ T-40 Torx (Hexalobular) Gages are manufactured to ISO 10664 Standards.
T40 Gage Set includes:
** GO and NOGO Torx gages can easily be customized. Call us with your dimensions at 239-628-4800.
Gauge Tolerances Conforms to ISO 10664
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