Abstract: A broaching tool has a plurality of cutting teeth for broaching a small, deep hole with high precision and surface finish. Three to eight teeth are engaged in the hole for cutting at any one time. For broaching sticky metals such as stainless steel, each cutting tooth has a face angle, backoff angle and rise which are sufficiently large to prevent thermal hardening of the hole surface. A ring is provided between the front face and land of each cutting tooth having a width selected to prevent formation of axial and ring-shaped tool traces. V-shaped notches having a large radial angle and a small backoff angle are formed in the land of each cutting tooth to break chips and prevent clogging. The tool further includes a rear pilot having a plurality of smoothing teeth with a diameter larger than the finished diameter of the hole. A set of rough and fine broaching tools can be provided, with the fine tool being processed to convert it to a rough tool when it is worn beyond tolerance.

Abstract: A non-toxic coolant/lubricant suspension is provided which is specifically designed for use in extremely high-load, high-stress machine operations, such as broaching. The composition of this coolant/lubricant includes about 1 to 15 wt % of molybdenum disulfide (MoS.sub.2) powder; about 1 to 7 wt % of soap flakes; about 6 to 12 wt % of a liquid polytetrafluoroethylene suspension; and about 66 to 92 wt % water. The liquid polytetrafluoroethylene component, which is a water-based suspension of polytetrafluoroethylene, serves as a replacement for toxic CCl.sub.4, which has been used to increase lubricity in coolant/lubricants comprising molybdenum disulfide. The replacement of CCl.sub.4 with liquid polytetrafluoroethylene in the present composition results in a non-toxic but still highly effective coolant/lubricant.

Abstract: A non-toxic coolant/lubricant is provided which is specifically designed for use in extremely high-load, high-stress machine operations, such as broaching. The composition of this coolant/lubricant includes about 8 to 15 wt % of molybdenum disulfide (MoS.sub.2) powder; about 2 to 6.6 wt % of soap flakes; about 6 to 12 wt % of a liquid polytetrafluoroethylene suspension; and about 66.4 to 84 wt % water. The liquid polytetrafluoroethylene component, which is a water-based suspension of polytetrafluoroethylene, serves as a replacement for toxic CCl.sub.4, which has been used to increase lubricity in coolant/lubricants comprising molybdenum disulfide. The replacement of CCl.sub.4 with liquid polytetrafluoroethylene in the present composition results in a non-toxic but still highly effective coolant/lubricant.

Abstract: A broaching tool has a plurality of cutting teeth for broaching a small, deep hole with high precision and surface finish. Three to eight teeth are engaged in the hole for cutting at any one time. For broaching sticky metals such as stainless steel, each cutting tooth has a face angle, backoff angle and rise which are sufficiently large to prevent thermal hardening of the hole surface. A ring is provided between the front face and land of each cutting tooth having a width selected to prevent formation of axial and ring-shaped tool traces. V-shaped notches having a large radial angle and a small backoff angle are formed in the land of each cutting tooth to break chips and prevent clogging. The tool further includes a rear pilot having a plurality of smoothing teeth with a diameter larger than the finished diameter of the hole. A set of rough and fine broaching tools can be provided, with the fine tool being processed to convert it to a rough tool when it is worn beyond tolerance.