depending on how many of these bushing that there are for you to have to make, it may be worthwhile to have a broach made so that you can cut both sides at one time.
if it is a job that will only be a couple of them at one time, or one once in a while I would set up and figure out how to drill the thru hole then use an endmill to open a slot in the end for the drive stud to fit into. a lot less work that way.
Just out of curiosity, what exactly does this mate with? I'm wondering if it needs to me metal or could be made from an acrylic or plastic etc.
A broach made to cut both sides at once is easier to make. However, I believe the force required to push it through the hole would be far too great.
Looking further at the photo makes me wonder, are the flats the full length of the bore? If they are do they have to be? If a smaller length of the "keyed" portion would work, say, 6-7mm it could be done with a file.
Hi guys,thank you for your suggestion. I don't think I'm ready to make a broach. Heat treating and hardening are skills that I've yet to learn. I may just drill thought and finish the 1mm odd thickness by a file.
The material in use has to be 304 SS as it will be submerged in a drinks dispenser. I've not have the chance to see the bushing in use but was told that it is inserted in a motor shaft with flats at the end. I don't have time to visit my dad's office though I would very much love to - there is a machine shop next door...
The making of the bushing will be ongoing though the quantity is unlikely to be big. For this model of the dispensing machines, he only need 3 for a start.
Regards,
Wong