Primary process: Broaching. The full route, materials, tolerances and design tips for an internal profile, with an indicative cost.
BroachingPrimary process
MachiningFamily
8Route steps
+/-0.02mmTypical tol.
An internal profile is primarily made by Broaching. Broaching pushes or pulls a toothed tool through or across a part, each tooth cutting a little deeper, to form a precise internal or external profile in one pass. Below is the full route to make an internal profile, the materials it suits, the tolerances to expect and the main design points. The route is free, from the finder.
Step by step
How an internal profile is made
The usual route, raw material to finished part. The amber step is where the internal profile gets its basic shape.
Stock
Start from bar, plate or billet sized for the internal profile.
Broaching (roughing)
Rough out the main shape, leaving stock on the critical surfaces.
Tooling High (broach) Tolerance ±0.025 to 0.1mm Lead 8 to 16 weeks
Finish machining
Take the finishing passes that bring the internal profile to tolerance.
Tooling High (broach) Tolerance ±0.025 to 0.1mm Lead 8 to 16 weeks
Holes and features
Drill, ream and tap, and where needed broach splines or cut gear teeth.
Tooling None Tolerance ±0.05 to 0.2mm Lead hours to days
Heat treatment
Harden and temper if the internal profile must resist wear or load, then finish-grind.
Tooling n/a Tolerance can distort Lead days
Grinding
Where the internal profile has bearing or sealing surfaces, grind them to the tightest tolerance and finish.
Tooling Low (wheel) Tolerance ±0.002 to 0.02mm Lead days
Surface finish
Anodise, plate or coat for wear and corrosion resistance.
Tooling Low Tolerance adds microns Lead days
Inspection
Measure the internal profile against the drawing, on a CMM for close work.
Need the real cost for an internal profile? The free route above is yours. Unlock the full dossier to quote and source it.
Keyways, splines, internal profiles; the custom broach is the cost, then it is very fast per part.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for an internal profile at your volume, in your currency, are in the dossier.
MODEL EST.
$60 to 165per part at 1 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on an internal profile and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
A quote checker that tells you if a supplier quote is fair, and the red flags to watch
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An internal profile is primarily made by broaching. The route is: Stock; Broaching (roughing); Finish machining; Holes and features; Heat treatment; Grinding; Surface finish; Inspection.
What does an internal profile cost?
It depends on size, tolerance and volume. As a rough ballpark it starts around $60 to 165 per part at 1 off and falls with quantity. The dossier gives should-cost at your exact volume and currency. A model estimate, not a quote.
What material is an internal profile made from?
Common choices are Steels (annealed); Stainless.
What is the main process for an internal profile?
Broaching. Keyways, splines, internal gears and odd-shaped holes in volume.
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
