cutting 1/4" keyway 1.5" thru 1" bore(couplings) using Matsuura MC-500V. any ideas?

[AAYoung]

Hello,
Looking for a way to leave the old keyway broach and shims in the box.
What tooling or process do you use to cut keyways using a cnc mill?

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[Jim Dawson]

Two options come to mind. You might be able to use a rotary broach, dunno if they will cut keyways. The other option would be to put a square tool bit in the chuck and turn the machine into a vertical shaper or jumping jack. Neither would be a good option IMHO.


You could do what I did and make a broach press with an 18 inch stroke. I built mine out of a cheap Chinese wood splitter. Makes quick work out of broaching holes and keyways.

Here is a picture of it rigged as a mini press brake, can't find the broaching pictures

[warrenb]

What kind of mill? On my Fadal machines you can lock the spindle and use an insert like a vertical shaper. Imagine a boring bar that could hold your cutter. Then you just do a plunge then retract, then stepover, etc...

[AAYoung]

This is a bimonthly repeat job. Hoping for an insert or rigid tool. thanks

[ToolHIT]

One option is a CNC Single Point Keyway Broaching Tool for a 1/4" Keway x 1.5" Depth on a CNC Mill. Here is a 1/4" Keyway x 2" Max DOC x 3/4" Shank Diameter Keyway Broaching Tool designed to be run in a CNC Vertical Machining Center:
https://www.toolhit.com/products/69116

Here is how to run it in a CNC Mill:
A collet will hold the tool shank and provide timing orientation. With the spindle locked the broach can be brought in line with the pre-pared bore diameter and chamfer lead of the part to start broaching the keyway at a speed of 10-30 IPM at .003"-.005" depth of cut per pass. Use flood coolant for lubrication during cut. Once the initial process is achieved you can speed it up to 50-80 IPM. The in-feeding cycle is repeated until you get to the desired depth of the keyway. In a blind hole you need to remove chips by either prior trepanning at the bottom of the keyway area or a pre-drilled hole at the bottom of the keyway location. For a thru hole you can broach right thru but do not disengage the part.

Hopefully this helps, if you have any questions let me know.

Thanks!

Mike

[AAYoung]

Looks like what I was thinking of. thanks