Handwheel broaching is the process of cutting keyways into handwheels in large volume production. That is why there are “standard sizes” for shafts, keyways, and handwheels.
Custom keyways and keyway style handwheel replacements in small numbers are done either with a process called wire EDM, or sometimes by a laser or waterjet. Keyways have very sharp corners and that can be a manufacturing challenge for low volume applications which do not justify a custom broaching tool.
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