Technical Foundation
What Is a Stud and Keyway Punche?
A keyway punch forms or broaches a rectangular slot (keyway) into a bore or shaft so a key can be inserted to lock a gear, pulley, or coupling against rotation relative to the shaft — an alternative to cutting the keyway with a broach and arbor press when only occasional or field work is needed. A stud punch forms or clears a round hole sized for a stud, pin, or fastener, typically used in sheet metal or thin-wall stock in a punch press.
Punch geometry and hardness are matched to the workpiece: punches for hardened or stainless stock use higher-hardness tool steel (often A2 or D2) with a more generous relief angle to reduce galling and extend life, while punches for mild steel or aluminum can use a more economical O1 tool steel. Keyway punches must be sized to standard keyway width/depth tables (per ANSI B17.1) so the finished slot accepts a standard key stock size without further machining.
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| Spec | What It Means | Why It Matters |
|---|---|---|
| Keyway Standard | ANSI B17.1 keyway width/depth by shaft diameter | Ensures the punched slot accepts standard key stock without hand-fitting |
| Punch Material | O1, A2 or D2 tool steel, hardened and ground | Higher-alloy steels (A2/D2) hold an edge longer against hardened or abrasive stock |
| Shank Style | Round shank, punch-press shank, or broach-style with pilot | Determines compatibility with a given press, holder, or guide bushing |
| Clearance/Relief Angle | Ground relief behind the cutting edge | Reduces friction and galling during the punching stroke, extending tool life |
| Application Method | Single-stroke press punch vs. progressive broach | Broaching gives a cleaner finish for precision work; press punching is faster for production runs |
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Applications
Where Stud and Keyway Punches Get Used
Stud and keyway punches are specified anywhere a hole or slot needs to be formed in metal stock without a full machining setup.
Power Transmission Assembly
Punching keyways into shafts and hubs during assembly of couplings, pulleys and gear drives.
Sheet Metal Fabrication
Stud punches forming fastener clearance holes in enclosures, brackets and chassis panels.
Machine Repair & Field Service
Portable keyway punch sets used to cut a replacement keyway on a shaft without removing it for machining.
Motor & Pump Rebuilding
Re-cutting worn or damaged keyways on motor and pump shafts during rebuild and repair work.
HVAC Equipment Manufacturing
Punching stud and mounting holes into ductwork and equipment panels during fabrication.
Tool & Die Shops
Custom punch and die sets built for specific stud or keyway geometries not covered by standard sizes.
FAQ
Stud and Keyway Punches Questions, Answered
What's the difference between a keyway punch and a keyway broach?
Both cut a keyway slot, but a broach is pulled or pushed through the bore in a single continuous cutting pass using a rack of progressively larger teeth to remove material gradually, while a keyway punch is typically struck or pressed to shear or form the slot in one or a few strokes — broaching gives a cleaner, more precise finish while punching is faster for field or lower-precision work.
How do I determine the correct keyway size for a shaft diameter?
ANSI B17.1 tables specify standard keyway width and depth as a function of shaft diameter — always check the shaft diameter against that standard rather than guessing, since an undersized keyway won't accept the correct key stock and an oversized one weakens the shaft unnecessarily.
Can I use a keyway punch on hardened steel shafts?
Only with a punch made from a higher-hardness tool steel such as A2 or D2 with adequate relief grinding — a standard O1 punch will dull or chip quickly against hardened or stainless shaft material, so match the punch material to the shaft's hardness before attempting the cut.
Do stud punches work on stainless steel sheet metal?
Yes, provided the punch is rated for stainless and press tonnage is sized for the higher shear strength of stainless versus mild steel — using a mild-steel-rated punch on stainless typically leads to premature edge wear or punch failure.
What's the benefit of a broach-style keyway punch with a pilot?
The pilot registers in the existing bore to keep the punch centered and aligned with the shaft axis during the cut, which prevents the keyway from wandering off-center — important when the keyway must align precisely with a mating key on an assembled shaft.
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