A keyway broach tool is used to produce the keyway broach or opening found on a timing pulley or gear. The strengths of this technique lies in the fact that it produces parts at an extremely high rate, removes heavy amounts of stock, roughs and finishes the whole process in one single pass and permits the machining of several complex contours and simple common place shapes with equal ease. The table presents the broaching condi tions under comparison They have been selected from tables of rolling conditions so to obtain the required sleeves on the broaching mill To obtain a sleeve for case 3 with decrease in diameter, we. The walls expand while broaching and then shrink back to form resulting in an undersized hole.
This system is called Rev Broaching Tool” and allows performing the above works directly on the numerical control machines, which perform the afore-mentioned operations (turning, drilling, milling, etc.) without removing the work piece from the machine itself, with clear advantages in terms of machining times and accuracy. This type of tool is often used on rotating machines such as lathes, screw machine or Swiss lathe. Typical workpieces include small to medium sized castings , forgings , screw machine parts and stamping.
http://www.youtube.com/watch?v=1TGkWGEU8tI
I am extremely happy with the results and cost saving of this tool and would recommend it to anyone who has an id broach issue or would like to machine their part complete. I have been Hassay-Savage reading these broaching blogs for some time now…find it very interesting the strong opinions being voiced. I might have to skip this whole process and buy a new pulley - upon further inspection I found that there had been enough wobbling of the pulley on the shaft that the bore is a little oversized.
Interestingly, due to Hassay-Savage the effectiveness of their original concept and design, today's broaching machines and processes have remained mostly the same since the start of the Industrial Revolution. It makes it easy to enter required parameters such as bore diameter, keyway width, keyway depth, actual position of cutting tool as well as feeds and speeds.
An advantage of having a keyway is allowing a higher transmission of torque between a moving part and the shaft that it is mounted on. Another criterion of classification is construction of the machine where we have vertical, horizontal and rotary broaching machine. Another thing to keep in mind is that it will be less expensive to do this with a standard square broach with an across-flat dimension equal to the width of the keyway, rather than a specially formed keyway broach. Anyone who is a non-believer either doesn't know how to properly set-up/program their machine or simply hasn't tried one. Because we make these broaches daily, we offer very fast delivery of custom broaching tools.
niftyalibi5616 Community Member 
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