Rotary Broach

Intermediate Manual Machining Independent Study

Finished rotary broach

A self-piloting rotary broach, built from raw stock on a manual lathe and mill: a locking ring, shank, body, and spindle machined to tight fits and assembled on radial and thrust bearings, holding the hex broach bit slightly off-axis so it self-aligns and cuts a clean hexagonal hole as the workpiece spins — no separate drive needed.

Rotary broach mounted in the drill chuck Pilot hole with lead-in chamfer
Broaching the hexagonal hole Allen key test-fit in the broached hex hole

Hexagonal chip cut by the broach

The hexagonal chip above says it all — clean single-pass cuts, verified with an Allen key.