Titanium Broaching and CNC Machining for Internal Profiles and Keyways

Background: Internal Profiles and Keyway Requirements

Internal profiles and keyways are critical features in many industrial, automotive, and aerospace components. Titanium’s strength and corrosion resistance make it an ideal material for high-performance keyways, shafts, and mating components.

In this case, the customer required titanium parts with precise internal profiles and keyways, demanding tight tolerances and smooth finishes. Titanium broaching combined with CNC machining was selected to achieve these requirements.

Material Selection and Titanium Machinability

Titanium alloys were chosen for their durability, corrosion resistance, and machinability characteristics. Machinability challenges included:

• Work hardening during cutting

• Maintaining tolerance on internal profiles

• Avoiding distortion in thin-walled or delicate components

Understanding the machinability of titanium alloys ensured successful broaching and machining operations.

Titanium Broaching Process

Titanium broaching operations included:

• Internal profile broaching for keyways

• Controlled feed rates to minimize work hardening

• Precision alignment to maintain concentricity

Broaching titanium ensured accurate, repeatable internal features suitable for assembly.

CNC Titanium Machining Integration

After broaching, CNC machining operations were performed to:

• Finish external diameters and surfaces

• Drill mounting holes or tapped threads

• Ensure overall dimensional accuracy

Precision titanium machining ensured the final parts met design specifications.

Dimensional Accuracy and Surface Quality

All critical dimensions, including internal keyways and external surfaces, were held within ±0.01 mm. Surface finishes were optimized for smooth assembly and long-term wear resistance.

Inspection and Quality Assurance

Inspection methods included:

• CMM inspection for internal profiles and keyway positions

• Gauge measurement for critical diameters

• 100% visual inspection

These steps ensured all machined titanium parts met exacting standards.

OEM and Engineering Collaboration

Engineering teams collaborated to:

• Optimize broaching and machining sequences

• Ensure correct tool selection and cutting parameters

• Validate prototypes before batch production

CAD, CAM, and CAE tools supported STEP, DWG, DXF, IGS, STL, and PDF formats.

Applications of Broached Titanium Components

Titanium broaching combined with CNC machining is widely used for:

• Automotive transmission components

• Aerospace coupling and shaft assemblies

• Industrial machine parts requiring precision keyways

These processes ensure strong, accurate, and durable titanium components.

Conclusion

This case demonstrates how titanium broaching and CNC machining produce precise internal profiles and keyways. By addressing titanium machinability challenges and implementing strict inspection protocols, reliable and high-quality machined titanium parts were delivered for demanding industrial applications.