InternalkeywayCutting tools

Milling an internal keyway requires the cutting tool, e.g. an end mill to to cut at 90º along the bore length. This kind of operation will usually require an angle head to dive into the bore vertically. The keyway is machined by removing material with the rotating cutting tool which is clamped to the angle head.

Wire-Cut EDM (Electrical Discharge Machining) is a process of cutting electrically conductive materials with high precision. It uses a thin, electrically charged wire to cut the required keyway by eroding material via electrical discharge.

KeywayBroach

In this comprehensive guide, we will discuss seven popular internal keyway cutting methods. We will explore the advantages and limitations of each method, provide use case examples, and offer best practices to help you make an informed decision.

Driven broaching heads (live broaching units) are specialized tools that can be mounted on CNC lathes with C-axis or CNC milling machines. These driven tools convert the rotary motion from the turret/spindle to linear motion to drive an inserted broaching tool through the workpiece.

How to cut akeywayby hand

Keyway cutting using this method on a CNC lathe or machining center eliminates the need to reclamp the tool on a separate machine in order to broach the keyway.

In this method, first the workpiece is clamped in position. Then the keyway is cut by the tool through a series of successive passes. The tool removes an equal amount of material with each pass until the required size of the keyway is achieved.

Cutting keyways with inserted broaching tools is a modern broaching method, using a tool holder with replaceable cutting inserts. These keyway cutting tools can be used on CNC machines and a variety of other machines for slotting and shaping. This offers greater flexibility and reduced tooling costs compared to traditional broaching.

Cutting internal keyways is an essential task in many industries, and selecting the most appropriate method for a particular application is critical to achieving the desired results efficiently.

Keyway toolingkit

Shaping or slotting is a method that involves using a reciprocating single-point cutting tool to remove material and create the keyway. The cutting tool moves horizontally or vertically along the workpiece, gradually cutting the internal keyway with each pass.

During the machining operation the lower body of the angle head needs to dive into the bore to cut the internal keyway. So this method is suited for workpieces with a bore large enough to accommodate the angle head.

Keyseating is a method that uses a reciprocating cutting tool, called a keyseater or keyway cutter, to cut the keyway. The cutting tool is mounted vertically in the machine and moves up and down while the workpiece remains stationary.

Shaftkeywaycutter

Keywaycutting tool for Lathe

The operation is performed on dedicated machines such as a shaper or a slotter. As for cutting tools, either integral keyway cutting tools or inserted broaching tools as in the second method can be used. An adapter might be necessary to clamp the tools depending on the machine type.

Broaching, keyway cutting with inserted broaching tools, keyseating, Wire-Cut EDM, shaping, milling, and keyway cutting with driven broaching heads each offer unique advantages and limitations.

Cutting internalkeywaymilling machine

Gisstec, with over 30 years of experience in clamping technology, manufactures angle heads, broaching tools, live broaching tools and turning tools with highest quality standards and distributes the products worldwide with excellent customer service, certified with DIN EN ISO 9001:2015 Quality Management System.

Keyways play a crucial role in mechanical systems, enabling power transmission between shafts and other machine elements. Cutting an internal keyway can be a challenging task, but with the right method and tools, it can be done with precision and efficiency.

This process is highly accurate and can be used to machine intricate keyway profiles in conductive materials. In addition, it is particularly effective in cutting precise keyways when working with hard materials.

The ultimate choice will depend on the size and geometry of the workpiece, keyway dimensions and quantity. By understanding these factors and applying best practices, manufacturers can make informed decisions and optimize their keyway cutting processes to maximize efficiency, precision, and overall performance.

Machine: One of the following: CNC Lathe, CNC Machining Center, Slotter Machine (Slotting Machine), Shaping Machine, Conventional Lathe, Milling Machine

Broaching is a widely used method for cutting internal keyways, involving the use of a broach—a specialized cutting tool with a series of progressively larger teeth. The broach is clamped on the broaching machine and either pulled or pushed through the workpiece to broach the keyway.

Keyway toolingcost

This high-speed broaching method is commonly used on CNC lathes. It creates keyways similarly to the second method, which utilizes static broaching tools. However, driven broaching tools are remarkably faster, exceeding the speed of static tools by over 10 times.

It’s also called static broaching tools since the Z-axis movement necessary for chip removal comes from the machine itself. On the other hand, a driven broaching unit generates the back-and-forth movement in Z-axis by itself. (See third method for details)