Spline cutting: methods, selection of equipment and tools

Tapping threads

Types of taps

Rolling tap (left) and regular cutting tap (right) Rolling taps cutting taps
Rigid tapping, tapping heads and floating tap chucks

Selecting the tap you want to use is not everything. You must adapt the tool holder correctly to your machine. Taps must be inserted in such a way that the feed rate is synchronized with the number of spindle revolutions, depending on the thread being cut. Too large or small a value puts pressure on the tap and creates problems. The value depends on whether your machine can accurately synchronize the feed rate with the spindle speed. If so, the tap may simply be clamped in the spindle. Otherwise, you need a holder with play so that the tap is fed into the hole due to its rotation as the thread is cut. Free play along the rotating axis will relieve spindle pressure while maintaining feedrate.

Blind holes are not easy to achieve without hard tapping because the spindle may still spin for some time after the stop command and it will be difficult to get it to spin just the right number of times. The backlash tool holder described above can help if you stay within the backlash limits.

Two types of holders used when rigid tapping is not available are the die head and the floating chuck.

Standard Die Head:

The die head has a clamp, friction clutch, axial free play and a reverse device that automatically changes the direction of rotation when the feed direction changes. Threading heads were originally created to make threading easier on drill presses and hand-held milling machines. They can be used on CNC machines, although they are not as common as rigid tapping and floating chucks.

Standard floating cartridge:

These holders are spring-loaded along an axis and allow the tap to find its own position as the thread is cut.

Tips for cutting threads

– Our tip #1 – Avoid tap breakage at all costs

: Drill the correct size holes to avoid excessive torque on the tap.

– Important for beginners: Avoid taps from hardware stores! Tools made for machine tools are not as expensive and work much better.

– Use a knurl tap

, if this is possible, such a tap is more durable (i.e. less susceptible to breakage), and the thread will also come out stronger. Additionally, these taps do not produce chips, so chips will not get stuck in a blind hole. Their only drawback is the limited rigidity of the material on which they can be used.

– Consider using a good lubricant

. You can place a cup of oil on the machine table and g-code it to drop the tap into the cup before starting work.

– Consider difficult holes with re-tapping threads

. For the most part, you will want the tap to retract when cutting hard to synchronize it to the same thread as it moves in and out of the holes. Ratchet tapping is used with cutting taps only. Retapping is also an excellent way to remove long, stringy chips that form when cutting plastics and some other materials.

– For the hardest materials, and especially when the cost per broken tap is very high, consider thread milling

. The likelihood of breaking a thread cutter is much lower. And even if it does, it won't get stuck in the hole, which would happen with a tap.

Required materials and tools

Such work is carried out in specialized workshops. In some cases, the repair and restoration of such products is carried out in a home workshop equipped with the necessary machines.

In the first case, to carry out the above operations, use:

lathes or milling machines;
special slot cutting machines;
welders;
mechanical hammer;
Hydraulic Press;
galvanic equipment;
point machines;
manual processing tool.

Home workshop options are limited. For independent work, use the following devices to restore such connections:

household lathe or milling machine;
small press;
electric sharpener;
welding machine;
set of hand processing tools.

With a small set of equipment, good specialists are able to restore a damaged connection.

Cutting splines on shafts, axle shafts, bolts, and holes

A spline connection is used to transmit rotational motion between shafts and bushings. Unlike a keyed connection, it provides better centering of the parts. At the same time, the load on some elements is significantly lower, and the strength under dynamic and variable loads is significantly higher. This type of connection consists of teeth of a certain length, connected as a whole to a rotating body.

There are three types of spline connections:

Cutting splines in the mechanical engineering industry is carried out mainly on milling equipment, which has special requirements for accuracy.

How to shorten axles: GAZ, UAZ, Moskvich?

here are some photos

If anyone needs it, I can post a shortened axle shaft.

Ildar76 wrote: Who needs it, I can post a shortened axle shaft.

I really need photos

I have to run for an hour, and I’ll take it off in the evening. Which bridge are you going to shorten?

Moskvichovsky, me personally. It is not possible to cut slots on the trim. It is necessary to join the splined part and the flange part. Another strange question: is it possible to assemble a front drive steering axle from a Moskvich differential and grenades, shafts and hubs of a front drive, for example a VAZ? If anyone. where I saw it, please post the link, I’ll figure it out.

Here's another. But the axle shafts must be cooked slowly, with smoke breaks. And before welding the front axle shafts, you need to make three four cuts near the joint with a grinder, thereby you kind of make keyways, and after welding you weld the whole thing.

umnyi wrote: kanol How many ears have become, the reel is not visible.

Twenty meters on center.

Ildar76 wrote: you need to make three four cuts near the joint with a grinder, thereby you are making keyways, as it were,

Is it possible to find out why, in the sense of what gives what?

I also planned to make a couple of cuts with a grinder along the axle shaft at the welding site and insert some type of segment keys. I am a beginner in welding, and (probably) this can protect against possible rotation of the joined pieces.

Kulan69 wrote: this can protect against possible rotation of the joined pieces.

It’s somehow hard to believe, maybe the meaning is in something else?

tuger wrote: Is it possible to find out why, in the sense of what gives what?

Gives reliability. After all, look or think for yourself, welding around the circumference of the metal (half shaft) without chamfering is not at all reliable. And with the chamfer removed, the contact error increases. And when removing (with a grinder) longitudinal chamfers (pits), the contact area increases even more.

Kulan69 wrote: I also planned to make a couple of cuts with a grinder along the axle shaft at the welding site and insert some type of segment keys. I am a beginner in welding, and (probably) this can protect against possible rotation of the joined pieces.

Leaving the washer there unwelded is not the best option; it is better to chamfer it wider and up to the second shaft, so that the electrode three can reach the lower metal, and thus both the washer and welding are obtained. And if it bursts during welding, then you won’t get very far with these washers, because there remains a void (with the washers) and this is not good.

Ildar76 wrote: And when removing (with a grinder) longitudinal chamfers (pits), the contact area increases even more.

Weld one to the other - I understand, but make grooves on one and then weld them, due to which we get

Repair method

If earlier the repair of shafts and axles, restoration of spline joints using composites was considered a temporary solution, now we are ready to guarantee long-term operation of the machine after restoration. The main thing is to choose the right composition. For example, the shafts in the friction areas of the gaskets heat up during abrasion; in other areas, cavities and damage more often occur without changing the structure of the metal.

Examples of restoring a shaft for a bearing:

If the shaft can be removed and installed on a lathe:
Thoroughly degrease the surface
We mix the material correctly so that there are no air inclusions
We apply the material to a shaft rotating at low speeds. The first layer is a thin primer, as if rubbed into the surface, the second layer is applied in excess, without waiting for the first layer to dry.
After complete polymerization, grind the shaft “to size” at low speeds
If the shaft cannot be removed, then it can be repaired directly on site by pouring. You just have to make special, simple equipment, or pour the material directly into the cavity between the shaft and the bearing. Of course, preliminary operations are necessary:
1. preparation of the shaft surface - roughening, deepening (if necessary), degreasing
bearing - treatment with anti-adhesive material, alignment

The thickness and geometric shape of the shaft have been completely restored. We provide a guarantee on work for up to a year. The experience of our specialists helps to carry out repairs in a short time, so the equipment will return to work quickly.

Recovery process

First of all, the mechanism is dismantled, then the splines are separated, they are thoroughly cleaned, and the surface is degreased before further actions.

There are several repair options within the car service:

If the diagnostics reveal minor wear, then electric spark extension helps to restore the spline joint, after which grinding is performed. In addition, the splines located in the holes along the outer diameter can also be repaired by spreading. To carry out this procedure, a hydraulic press is required. With its help, special firmware is pressed through the slotted hole. Calibration is carried out with a spline broach, which is performed after the teeth are distributed, during which the extruded material is removed and the parts acquire the required size.
Spare parts can be rebuilt using toothing if the spline connection is centered on the inner diameter. For hardened parts, the shaft must first be annealed, then all the splines must be distributed in the axial direction (longitudinal), while adjusting the width to the required size, leaving an allowance of one or two tenths of a millimeter for machining. There are two options for performing this procedure: the first is distributing manually, the second is using chisels and stampings on presses. During the procedure, longitudinal marks are applied along the splines, along which grooves are then marked with a chisel, which are stamped.
It is possible to distribute the splines on a planer or lathe. To do this, a mandrel having a rotating roller in the shape of a double-sided cone is fixed in the tool holder; for processing, the shaft is placed in the center of the turning machine, or mounted on the table top of the planing machine. The roller is brought in using a caliper, then it is pressed into the tooth and several working strokes are made along the groove. The next step is electric welding, the grooves are welded, and the shaft is annealed and straightened, while the splines are brought to the nominal size and treated thermally.

After restoration, the part undergoes a thorough check, tests are carried out, after which it can be installed back.

If the surface of the parts has defects, such as burrs or sharp edges, then sawing is carried out, and chamfers are removed from the ends.

A necessary step after completing the repair work is balancing the driveshaft, which is best left to specialists.

REFERENCE: As a rule, a warranty on a repaired part is provided for a period of up to six months or a year.

Replacing a splined cardan and especially restoring spline joints is not an easy task and requires extreme precision so that the balancing is not disrupted and the mechanism subsequently works properly. When a problem has already been discovered, do not put off visiting a car repair shop - this will not only prevent subsequent inevitable breakdowns, but will also make driving safe again.

Spline cutting methods

Before cutting splines on the shaft, it is necessary to choose a method for centering the mating parts. The gear or bushing is centered as follows:

The first method is applicable in fixed joints that do not require increased hardness. Centering along the inner diameter is applicable to parts that have undergone hardening, and along the sides during reverse movement of the shaft and high torques.

Depending on the shaft diameter, spline milling is performed in one or two passes. Rough milling of splines on shafts can be done with disk cutters, and finishing milling can be done with a special hob cutter, which ensures the greatest accuracy.

Such complex spindle elements are usually planed on special semi-automatic planers, when there is a distance for the cutter to exit through the holes. All grooves are cut simultaneously with several cutters. The workpiece is mounted vertically and reciprocating movements are performed. After each stroke, the set feed motion is executed. Planing is used in mass production and provides high quality processing with a roughness of up to 0.8 microns.

Internal spline cutting is best done using broaching equipment. Each groove is processed in turn, but there are broaches for cutting several teeth at the same time. A highly efficient method for producing joints of this type is knurling. It is performed on special equipment using a knurling head, which has rotating rollers. With the help of these rollers, metal is extruded from the surface of the workpiece and a splined groove is formed. This method allows you to cut up to 18 teeth simultaneously and is used in large-scale production.

Manufacturing spline shafts for your mechanisms

Manufacturing and repair of shafts

In order for a shaft to operate truly flawlessly and to correctly transmit high levels of torque, it requires not only adherence to the design, but also equipment capable of performing the most delicate operations. The gear cutting production of our workshop is equipped with vertical milling and slot milling machines of the new generation. Most of them operate on numerical control.

In addition to the manufacture of spline shafts to order, the repair (restoration) service of these parts is also in demand. Even a perfectly assembled mechanism wears out over time. Especially the shaft, which is exposed to different loads. Splines and grooves suffer the most from friction. In addition to signs of wear, sharp edges, nicks and burrs may also appear on the part.

If restoration work is possible, the defects that have arisen are corrected using the methods of upsetting, crimping, knurling, spreading, straightening, pressing and others. These problems are most often solved using machining. But welding, surfacing, electroplating and metallization can be used along with them.

Making splines

Cutting splines on shafts, axle shafts, bolts, and holes

Errors in the manufacture of spline shafts

In order for the shaft in the mechanism to work flawlessly, high-precision technologies must be used in its production. The highest quality effect is achieved by manufacturing splines using CNC equipment. Attempts to perform the above steps manually result in uneven cutting of the splines. This is an obvious defect, threatening inconsistency of details.

Some problems may not be discovered immediately, but later. For example, in case of refusal from polishing, which has not only an aesthetic effect. Then the smallest roughness will remain on the surface of the part, which can lead to premature wear.

Manufacturing of shafts to order

Methods for cutting splines on shafts

Methods for making splines on bushings

Placing an order for the production of a splined shaft

Shaft classification

Cutting slots at home

Making splines on a shaft at home is an almost impossible task. It is very difficult to create a part in a garage or utility room with cut grooves of the same shape that have a uniform “step”, even if the master has experience and remarkable dexterity. However, some craftsmen still achieve the desired result with the help of an ordinary grinder.

But it’s one thing if you need to apply splines to a single axle shaft of a car, and quite another thing if you need a whole series of splined shafts and bushings for them. In this case, it is better to turn to a production facility with good capacity.

Slot manufacturing and cutting services

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product sample.

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Types of bits

The screwdriver accessories consist of the following accessories:

magnetic or regular bits and holders for them (extensions);
drills

The bit is a rod with six edges, on one side of which there is a working profile, and the other end is intended for fixation in a power tool chuck or in a holder. This special nozzle must be sized to match the type of fastener (self-tapping screw, screw, screw, bolt, etc.).

Drills for screwdrivers represent a separate category of equipment. They are taken from ordinary (unstressed) drills. In this case, the maximum diameter of the drills is limited by the largest cross-section of the tail section, which the tool chuck is capable of clamping.

Existing types of bits differ in the shape of their working part. Based on this feature, the following groups of this equipment are distinguished:

main (standard), which includes straight, cross-shaped, hexagonal tips, as well as in the shape of an asterisk and for bolts;
special, for example, bits equipped with spring clamps, limit stops (designed for screwing drywall sheets), triangular;
combined, in which the nozzles are equipped with two working parts of different shapes or sizes.

Bit extenders are divided into two types:

magnetic, holding the inserted nozzle due to the force of a magnetic field;
spring ones, in which the tail part is fixed rigidly.

Standard equipment

Standard attachments are included in any set; they are used most often in work. The very first of the variety of equipment to appear were straight (slotted) bits. This classic option is designed to work with screws or screws that have a straight cut. Spline equipment is marked with the letter S (from the word slot), next to which a number is placed. The number indicates the slot width, which ranges from 3-9 mm. The thickness of the tip is not specified, but its standard value is in the range from 0.5 to 1.6 mm. The marking located on the shank also contains an indication of the material from which the equipment is made.

There are spline bits with a gold titanium nitride coating. Then the marking contains the TIN designation. In this case, the width of tips with titanium coating can be from 4.5 to 6.% mm, and the thickness - 0.6-1.2 mm.

There are elongated spline-type nozzles. They are 5-10 cm long.

Cross-shaped (cross) bits are divided into two groups:

Ph (from Philips) - a universal type with a length of 2.5 to 15 cm (there are also 30 cm flexible holders), with a working part of four diagonal ribs;

PZ (Pozidrive) is a tool of different lengths, equipped, in addition to 4 main ribs, with four additional ones.

Philips equipment has four standard sizes: from Ph-0 to Ph-3. The number corresponds to the outer diameter of the fastener.

Pozidrive attachments come in the following sizes:

PZ0 are used to work with screws up to 2.5 mm in diameter;
PZ1 - they are used to tighten fasteners from 2.5 to 3.5 mm;
PZ2 are designed for 3.5-4 mm screws;
PZ3 and PZ4 allow you to work with large screws and anchor bolts.

Cross-shaped equipment is the most common compared to other varieties. It may also have a titanium coating.

The hexagonal bits are marked with the letter H (from the phrase Hex socket). Such attachments can be:

classic type, size 1.5-10 mm;

hexagonal in shape, but with an internal hole (their dimensions range from 1.5-6 mm);

elongated, with working part sizes from 3 to 8 mm and a length of 5-10 cm.

Star bits are marked with the letter T followed by a number. They are used in the assembly/disassembly of household appliances, as well as cars. They come in the following varieties:

Torx (classic), sizes T8-T40;

Torx Plus (their beams are less sharp), sizes from T10 to T40;

with titanium coating (TIN), sizes T10-T40;

with internal hole (standard size T10-T40);

elongated: sizes from T10 to T40, length 5-10 cm.

Nozzles designed for tightening or unscrewing fasteners with a hexagonal head (bolts, nuts) have a size of 6-13 mm. The most common of these are eight-millimeter bits.

Special attachments

Special equipment includes the following types of bits:

three-blade (Tri wing), sizes TW0-TW5;

four-blade (Torq-set, designated Gr), size 4-10 mm;

classic and elongated tetrahedral (Robertson square, with a square slot), designated by the letter R;

elongated and classic “fork” shaped (designated Gr).

There are also tips with other special shapes, but they are used extremely rarely.

Mechanical metal cutting

Mechanical separation is based on direct contact of the metal being processed with the cutting tool. The material of the tool, as a rule, is also metal, but of higher hardness.

There are mechanical cutting using scissors, saws, and cutters. A special case of mechanical cutting is impact cutting. Impact cutting or chopping with a guillotine is used at the stage of procurement work.

Types of equipment used for mechanical separation of materials:

band saw machines (LPS);
guillotines;
disk machines;
lathes with cutters installed on them;
slitting units.

Band saw cutting

Cutting material with a band saw is often used to separate long, sheet metal. The band saw is the main unit on the so-called band saw machine (LPS). The essence of the work of a band saw is the same as that of a regular hacksaw. The saw blade is enclosed in a large diameter band, one side of which has special teeth. The saw blade moves continuously due to the rotation of pulleys connected to an electric motor. The average cutting speed of the machine is 100 mm/min. The material for making the saw blade is carbon steel or bimetallic alloy.

The advantages of the method: accuracy, accessibility, low price of equipment, the ability to perform not only straight, but also angular cuts; a small percentage of waste, since the cutting width is only 1.5 mm.

Modern LPS models are equipped with electronics and additional equipment with which you can include the machine in the production line.

Impact cutting of metal on a guillotine

This type is usually called felling. The main application of cutting is the separation of sheet metal. It can be ferrous metal, various types of steel - stainless, galvanized or electrical steel.

The method is based on the use of mechanical devices: scissors, knives for cutting metal sheets. The metal sheet is placed on the working surface of the guillotine. They are secured using a pressure beam and the operation is performed.

The uniqueness of the method lies in the fact that chopping (cutting metal) occurs with a single blow of a knife along the entire length of the workpiece being cut. The result is an absolutely smooth edge without unnecessary edges or burrs.

Three types of guillotines are used in industrial production:

electromechanical;
hydraulic;
pneumatic.

In some industries, manual guillotine shears have been preserved, where the cutting mechanism is activated by pressing the pedal.

Disadvantages include noise during operation of the mechanism, limitations on the thickness of the workpiece, and differences in the width of the cut parts.

Cutting on a disc machine

The main advantage of this equipment is ease of operation, compactness, and versatility.

The role of the cutting tool is played by a disk with teeth protected by a casing. The disk is mounted on the surface of the desktop and driven by an electric motor.

Cutting with a circular saw is characterized by high cut quality, the ability to cut at an angle, and high processing accuracy.

A slitting unit is highly specialized equipment that is used exclusively for longitudinal separation of a metal workpiece.

The cutting process is fully automated. The operator monitors the process and controls the work from behind a special console.

The uniqueness of the method: the ability to divide sheets into narrow elements of long length (ribbons, strips, strips).

The general disadvantages inherent in all types of contact cutting can be formulated as follows:

cuts only in a straight line or at an angle;
It is problematic to obtain parts of complex configurations.

In modern technologies, the latest methods of metal separation are used, in particular, cryogenic (an operation using a supersonic flow of liquid nitrogen).

Cutting and cutting of metal are the primary procurement stages of processing metals and alloys. The use of straight-sided workpieces of the correct shape as the final product of metalworking is limited. After cutting by mechanical methods and gas-oxygen cutting, the parts are transferred for mechanical processing. But using thermal operations of laser and plasma cutting, you can obtain parts that are the final product. These will be parts of a complex configuration with cut holes, cuttings and other elements.

Sequence of actions

Regeneration of spline joints is carried out based on the results of an assessment of the condition of the entire joint. The procedure for carrying out repair or restoration work depends on the type of fit of the product and the degree of wear of each part.

The most common ways to eliminate found breakdowns include:

Solving these problems is carried out using the following methods:

mechanical processing (using metalworking machines, hydraulic presses, manual finishing);
welding and direction;
metallization;
galvanic method.

If minor defects in the slot appear, repairs can be made using the expansion method. To implement it, a hydraulic press is used. Under pressure, the material used for repair is forced into the bushing hole. Afterwards it is calibrated again. Similar actions can be implemented using, in other words, a slotted broach. All excess metal is removed. Afterwards it is milled and finished until the hole reaches the specified size.

In case of high degree of wear, surfacing is performed using an electric arc apparatus. Another repair option for high levels of wear is welding on the edges. Such methods, after proper processing, make it possible to obtain the original size of the groove.

Repair of splines is permitted when the groove is first enlarged and deepened. This operation allows you to remove a variety of causes of failure. Afterwards a stepped key is made for it. This option is used when other methods are not suitable.

Distribution is done in two ways. The first involves performing the operation manually. The second using pressing equipment and specialized tools. A longitudinal mark is applied along the slot with a core. Next, the grooves are made with a chisel. To enlarge them and give them the desired shape, chasing is used. Final processing is carried out on a lathe or planer.

The resulting grooves are completely welded. The splines are finished and subjected to heat treatment to give them very high strength.

Repair of spline joints where wear occurs in thickness is done using inverter devices. To fill the grooves, prepared rollers are placed along the splines. Subsequently, welding work is done.

Worn parts located in steel hubs are revived using the compression method. They are warmed up. Afterwards the prepared spline is placed into the bushing. Using a specialized punch, the part is clamped. A similar operation is performed using a mechanical hammer.

Products placed in cast iron bushings are revived by restoration on the shaft. Old parts are machined to their full depth. A new bushing is pressed into the resulting hole. The prepared slot is inserted into it.

Regeneration of developed landing sites is carried out using the method of supersonic metal spraying. This method does not require heating and melting. After metallization is completed, mechanical processing is performed. Regeneration of splined shaft joints is carried out in most cases by mechanical methods.

The main differences between the PZ spline

The PH profile was the only cross-shaped profile until Phillips improved it in 1966 by creating Pz (Pozidriv) splines and tips.

It has a number of differences from the launch vehicle profile:

In the corners formed by the intersection of the slots in the slot, there are 4 more small slots corresponding to similar edges of the bit. This is necessary for better centering of the screwdriver in the screw head.
In the RN, individual edges are not of the same thickness along their length and become thinner towards the end of the bit. This is done so that if the tightening force is too great, the tip will “pop out” of the slots and will not break off the head of the screw. In PZ bits, the edges are parallel along the entire length, which makes fixing the screwdriver in the screw more reliable, and the tightening force should be limited to the torque regulator by the screwdriver chuck.
PH bits have a sharpening angle of 55°, as opposed to the slightly sharper PZ, sharpened at an angle of 50°.

In fact, the main difference between a PZ bit and a PH bit is the clamping force. The head of the PZ screw is larger and allows you to tighten it with a corresponding bit with greater force, which is an advantage when making furniture. Therefore, this profile is used mainly in furniture production.

When assembling metal structures, PH screws are more often used, with smaller head sizes and tightening forces. To increase the pressing area, washers are additionally used, and if it is necessary to increase the pressing force, screws and screwdrivers are replaced with bolts and keys.

Screwdriver with slots PZ/S and PZ/FL for automatic machines

Practicing electricians know that connecting wires to low- and medium-power electrical appliances is done using screws Pz +/- or Ph +/-. These elements have a double slot - cross and flat.

In connection with the advent of these screws, tool manufacturers began producing electrician's screwdrivers with Pz/fl or Pz/s tips for circuit breakers and Ph/fl or Ph/s for starters, terminal blocks and other equipment.

Information! Previously, this profile was not standardized, so it was produced under different names - Fl and S.

The bit size depends on the hardware:

connecting wires to sockets and switches is done using the first number;
The terminals of modular machines and some types of starters are clamped with the second number.

The screws in these devices can be clamped not only with a Phillips screwdriver, but also with a flat-head screwdriver. This allows you to unscrew the fastener even if the slot is torn off. But the maximum clamping force of the connected wires is achieved when using a combination screwdriver Pz/Fl or Pz/Sl.

Such screwdrivers should be chosen only from well-known manufacturers. A tool of poor quality may break off the edge of the tip that fits into the flat slot of the slot, and if the flat tip can be sharpened again, then the Phillips screwdriver will have to be thrown away.

When tightening screws and screws with a tool with an incorrect profile, it leads to accelerated wear of the tip. Moreover, if the use of a PH screwdriver with PZ bolts is conditionally acceptable, then attempts to unscrew the PH screw with a PZ bit are guaranteed to lead to a negative result.

This is due to the fact that the additional edges will not allow the tip to enter the slot completely and engagement will occur only with the end of the tool.

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Spline cutting methods

Before cutting splines on the shaft, it is necessary to choose a method for centering the mating parts. The gear or bushing is centered as follows:

along the outer diameter of the shaft D;
along the internal diameter of the shaft d;
on the sides b.

Scope of use and features of spline connections

The production of splines is quite in demand due to the fact that the type of connection obtained as a result of the work operations performed is necessary in many areas of production and industry. Most often, spline connections are used when it is necessary to provide torques in the connections of a shaft with a gear wheel, pulley, coupling half, as well as a number of other parts. Basically, this type of connection is movable, that is, the bushing is capable of moving along the axis, the spline surfaces act as guides for the longitudinal movement of the elements. Spline connections are technologically complex, especially compared to keyed connections, but they provide higher capabilities. Thus, with their help it is possible to ensure excellent alignment of the bushing on the shaft, as well as transmit significant torques.

Spline cutting

You can create splines using one of four methods:

Milling. Used for single and small-scale production. Suitable for cutting on shafts, one or two cutters can be used.
Running in. This method is suitable for cutting on shafts in case of mass production.
Chiseling. Slotting machines for creating splines are used for cutting on bushings, including on their inner surface.
Broach. This method is also used on bushings, but is more expensive and of higher quality. Broaching requires a specific tool for each diameter.