How to mill keyways?

[Korver15]

So I have been wondering this for a while, but how do they cut the detailed keyways in plugs? It is too small to use an endmill and I wouldnt think think you could laser cut (maybe that is it)? Anyone have any insight?

[Anarchy_won]

you can do it with a Wire EDM machine.

[Riyame]

How do they cut keyways into lock plugs? They use a broaching machine. The broach is in the shape of the keyway and the plug is forced over it.

[oldlock]

^ What he said + the broaches are now (the ones I have seen) about a metre long. It's very interesting to see.

[Werewolf]

Barry Wels made a very interesting video on this , when Toool visited Ankerslot factory

[Papa Gleb]

I have always wondered the same and couldnt find any videos on yt. I always thought they extrude it. Thank so much for the video, its very interesting to see how fast this machine used 14 or 16 cutters

[Korver15]

OHHH that's so cool! So it progressively cuts with each tooth being more of the keyway and the keyway is the profile of the teeth. Thats awesome, thanks for the replies

[MBI]

Yep.

Except for the super-cheap zinc lock cores. Those are usually cast from molten zinc alloys. Usually with very simple keyways like M1 and KW1.

Also some cheap locks like postal locks can have cores that are pressure-cast from powdered Zamak or similar zinc alloys. I don't remember the correct industry term for the process. Basically instead of melting the zinc into a liquid they take powdered metal like zinc, pour a specific weight of it into the mold where it is compressed under high pressure until it more or less fuses together, then it's usually nickel plated to look nicer.

[Jaakko Fagerlund]

Yep.

Except for the super-cheap zinc lock cores. Those are usually cast from molten zinc alloys. Usually with very simple keyways like M1 and KW1.

Also some cheap locks like postal locks can have cores that are pressure-cast from powdered Zamak or similar zinc alloys. I don't remember the correct industry term for the process. Basically instead of melting the zinc into a liquid they take powdered metal like zinc, pour a specific weight of it into the mold where it is compressed under high pressure until it more or less fuses together, then it's usually nickel plated to look nicer.

Sintering

[MBI]

Thanks Jaakko. The word was on the tip of my tongue and I just couldn't recall what it was.

[huxleypig]

They use a 'wobble broach'. I would very much like to have one for my mill. All manner of shapes can be cut then. They are pretty expensive though.