Abstract: A composite tooth-forming rack useful for pressure forming teeth in a workpart is provided and includes an elongated carbon steel base and an elongated toothed insert of high speed steel joined to the base by a metallic bonding agent, such as silver solder, having a melting temperature below the solution annealing temperature of the high speed steel insert and above the tempering temperature thereof so that the rack can be heat treated in conventional fashion to develop the required hardness in the toothed insert and at the same time bond the base and insert together.

Abstract: The broach manufacturing method includes a first turning operation in which the outer diameter of the puller portion, retriever portion and the toothed cutting portion are rough turned to within 0.030-0.050 inch of finished dimension. Also, in the first turning opertion, the cutting teeth are turned to include a gullet radius of finished dimension and an oversized hook angle intersecting therewith. Following a hardening treatment, the cutting teeth are turned to finished dimension in a second turning operation with the exception that the outer diameter and back-off angle of the finishing teeth are turned slightly oversize in the second turning operation followed by grinding to final dimension. The oversized hook angle of the cutting teeth is also nicked off during the second turning operation and blended with the gullet radius turned in the first turning operation. The turning operations are performed on a CNC lathe.