Varad Engineering manufactures precision surface broaches and flat broaches up to 1500 mm in length from its specialized Broach Manufacturing Unit in Mhalunge, Chakan, Pune. Engineered for external flat profile and contour machining, our surface broaches are backed by dedicated ELB SCHLIFF surface grinding and imported resharpening machinery.
Surface broaches are linear cutting tools mounted on broaching machine rams or tool holders to machine external flat faces, steps, slots, and contoured surfaces in high-volume production. Unlike internal broaches that require a pre-drilled starting hole, surface broaches operate across outer component surfaces to achieve high flatness and dimensional consistency.
Our workshop setup supports single-piece and segmented flat broaches up to 1500 mm in total tool length, accommodating long-stroke broaching requirements.
Designed to replace multiple milling passes with a single high-speed broaching stroke for external faces, connecting rod joint faces, bearing caps, and steering linkages.
Precision in surface broaches depends directly on the accuracy of the grinding machinery used to manufacture the body and teeth. Our facility includes:
High-precision German surface grinding machine capable of handling flat broaches up to 1500 mm length with rigid bed support.
Equipped with Arthur Klink, Pentagon, and Lapointe machinery dedicated to flat broach manufacturing and accurate tooth rake sharpening.
Universal milling machines and heavy-duty lathes support tool body profiling, slot milling, and mounting fixture machining.
Each surface broach is thoroughly inspected across step heights, tooth pitch, tooth face angles, and overall parallelism using calibrated equipment:
Electronica PP 300 H (10×, 20×, 30×)
Magnified visual verification of tooth rake, clearance angles, and gullet root radii.
63 Slips · Grade A Accuracy
Precision slip gauges for checking progressive step height increments along the broach length.
FIE Group Model RASN (10–150 Kgf)
Verification of core and tooth hardness to ensure wear resistance and tool life under load.
Comprehensive flat broach manufacturing overview.
View Flat Broaches →Internal key broaches with and without chamfer.
View Keyway Broaches →Contract broaching for customer-specific batches.
View Contract Broaching →Resharpening and regrinding on imported machinery.
View Regrinding →Manufactured at our Broach Manufacturing Unit in Mhalunge, Chakan, Pune and supplied to manufacturing customers based on their technical drawings.