Spline machining is an essential process in manufacturing torque-transmitting internal profiles for transmission gears, drive hubs, prop shafts, and gearboxes. Varad Engineering manufactures specialized combination and interspaced spline broaches with capacity up to 200 mm diameter and 2000 mm length from its unit in Mhalunge, Chakan, Pune.
Spline broaching is the primary method for cutting internal involute and straight-sided splines inside gears, companion flanges, drive sleeves, and transmission housings. Unlike milling, shaping, or wire EDM, internal broaching generates multiple spline teeth simultaneously along the full bore circumference in a single machine pass.
This high-efficiency cutting operation ensures consistent pitch spacing, tooth form accuracy, and concentricity with the component bore, meeting the tight tolerance requirements of Tier-1 automotive and mechanical assemblies.
Combination spline broaches integrate round sizing teeth and spline profile teeth on a single broach bar.
Interspaced spline broaches utilize alternating tooth sequences to distribute cutting load across deep tooth heights.
Our plant in Mhalunge, Chakan supports round broach manufacturing up to 200 mm diameter and 2000 mm length with dedicated grinding machinery:
High-precision spline grinding machine handling jobs up to 125 mm diameter and 2000 mm length.
Precision cylindrical grinding for round broach bodies and shanks up to 125 mm diameter and 1800 mm length.
In-house broaching setups allow contract broaching of client parts for batch production.
Spline broaches and broached components are verified on dedicated inspection equipment:
Model: Hoffler ZP 260
Measurement of gear tooth profiles, pitch errors, and involute geometry.
Model: KAPP NILES KNM 2X
Equipped with internal gear testing facility for checking internal spline forms.
0.75 mm – 10 mm (Least Count 0.1 mm)
Roller pin sets used for accurate measurement over pins (MOP) across internal spline spaces.