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I agree with dak1, the form looks pretty deep for rotary broaching. One problem is that rotary broaching deep lengths is prone to developing a twist due to the back-taper. The other is that as the...

Would you be able to set-up a fixture like this one so that you can use a rotary broaching tool? A guide keeps the hex aligned while it feeds into the hole. A similar fixture can be made for a lathe....

Here is a great video demonstrating the rotary broaching process using a Bridgeport:
Rotary Broaching on a Bridgeport - YouTube

Hello:

Not sure if this helps but Polygon Solutions will rent you a rotary broach tool holder for $100 for 30 days. For more details visit: Rotary Broach Tool Holders

http://blog.polygonsolutions.com/wp-content/uploads/2011/09/new-haas-st-polygonbroachsm.jpg
It's little hard to see here, but during the 2011 demo here in Florida I seem to remember noticing the...

http://blog.polygonsolutions.com/wp-content/uploads/2011/09/new-haas-st-polygonbroachsm.jpg

The Haas ST Lathe was set-up running sample aluminum parts. The live tooling worked well, and the...

Just for reference, rotary broaching 3-5mm tooth height at 20mm depth is over the normal recommended stock removal of .010-.030". You also might consider some type of shaping or single spline...

Click here to find your local dealer:

CNC - Haas Automation, Inc. - LOCATE DEALERS

Demo Day 18 - September 14th, 2011
Haas Factory Outlet
913 US Hwy 301 South
Tampa FL 33619
Tel:877-504-7208

Your Source for:
Haas CNC Machine Tools
www.haasflorida.com
www.haascnc.com

Did you end up trying the 2 or 3 point broach? I'm just curious about how it turned out. You could also do a rectangle and rotate that right? Thanks.

Don't forget to look around on craigslist.org too, lots of deals there if you get on at the right time.

This problem illustrates the need for better translation software. I'm constantly amazed at how many times we try jump through hoops when a good CAD translation software should be able to do the...

Have you looked into Rotary Broaching?