Posted by JasonB on 06/07/2023 13:51:45:
The Hemmingway item is only said to suit small polygons upto about 7mm AF nowhere near what the OP wants to do.
From most of the posts on this thread it seems others have only done small holes mostly in softer materials.
Perhaps the reason for others doing small holes in softer materials has something to do with the forum title MODEL Engineering, perhaps we should refer the OP to a full size engineering forum, he will still have to realise though that the protrusion or null point is critical regardless of the size of the broaching tool. Bigger broaching tools do bigger hexagons / squares and bigger forces are created and bigger prices for tools, seems that the cheapest tool is around about a grand in the UK, I will not comment further but there are many other ways to produce what he hopes to achieve by broaching.