Hex Rotary Broaches

1/2 Shank

View our large selection of .500 inch shank diameter hex rotary broach sizes.
Size Range .081 to .750

1/2 in. Shank Diameter

Order Hexagon Rotary Broach with 1/2 in. shank diameter x 1.75 inch length.View Sizes

8mm Shank

View our large selection of 8mm shank diameter hex rotary broach sizes.
Size Range .050 to .410

8mm Rotary Broaches

Order Hexagon Rotary Broach with 8mm shank diameter x 1.25 inch length.View Sizes

Micro Broaches

8mm shank diameter x 28mm overall length hex micro rotary broach sizes.
Size Range .050 to .240

8mm x 28mm

Order Hexagon Rotary Broach with 8mm shank diameter x 28mm length.View Sizes

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.

• Custom Dimension
• Cut Length
• Dish Angle
• Vent Holes
• Tolerance
• Corner Radius

Our Hex Rotary Broaches can be ordered in custom dimensions. Can’t find the size you’re looking for? Polygon Solutions provides fast delivery on custom ½” or 8mm shank hexagon rotary broaches. Simply specify the desired across flat dimension when ordering. Polygon’s manufacturing tolerance is +0/-.0005”. For example, a custom hex broach with 0.1234” across flat dimension is part number H01234B.

If you need a hex rotary broach to cut deeper than our standard dimensions, perhaps to clear a counter-bore, you can request a custom cut length. Custom cut lengths may be limited by the back-taper on the side of the hex broach, or manufacturing limitations. Please call (239) 628-4800 for more information. Rotary broaching more than 1-2x the across flat dimension may not be successful. Broaches may also be weakened because of a deeper cut length.

If you need a hex rotary broach to cut deeper than our standard dimensions, perhaps to clear a counter-bore, you can request a custom cut length. Custom cut lengths may be limited by the back-taper on the side of the hex broach, or manufacturing limitations. Please call (239) 628-4800 for more information. Rotary broaching more than 1-2x the across flat dimension may not be successful. Broaches may also be weakened because of a deeper cut length.

Single vent holes are standard with hex rotary broach forms larger than .079″ and allow air and/or fluid to pass though the hex broach and reduce any hydraulic pressure that may occur when broaching a blind hole. Polygon’s rotary broach tool holder is also designed with this feature. However, an additional cross vent hole can be added for holders without the pressure relief system.

All of Polygon Solution’s hexagon rotary broaches are manufactured with a +0/-.0005” tolerance. However, hex broaches can be manufactured to a tighter +0/-.0004” tolerance. If you want to use the broach as a gauge, the hex broach can also be manufactured without a back-taper. For more information, see Rotary Broach Gauges.

If you part allows for a corner radius, we can add a spun ground diameter to the hex broach to remove the sharp corners. The spun ground diameter is useful for reducing the chip size and pressure required for long tool life and successful rotary broaching operations.