RFQ spline broaching

[timmydabull]

RFQ spline broaching part file attached

i will be providing material 3.5x1.140 6061

DWG file is attached

thank you

[timmydabull]

here is a jpeg of the part,will send files to any who request and furnish email address.

there will be 10 parts in this order.

[makinoman]

I am not sure that you will find someone who has a broach to do that. And a broaching tool for that would most likely run you alot of money. Hard to tell the thickness of that part, but you can probably expect the broach for that to be no less than $1100. Although I could be wrong, I wish you best of luck in finding someone who can do that for you.

[timmydabull]

the part is 1 inch thick.

i called slater tool and they havent gotten back to us on whether they can supply a broach fir this.

$1100 is right on the money for the tool and toolholder.

how do you reccomend i cut this part.

allready obtained quote for EDM $30 per part does this sound correct for a part 1 inch thick 3.5 inch chain.

[mc-motorsports]

Yep, I was going to say EDM, that's the way to go for low production.

[NC Cams]

Or someone who has a Bridgeport broaching head lying around.

WE have one but havent' used it enough to help out with any level of expertise.

Go with the EDM....

[makinoman]

I'm not too familiar with edm but it sounds like that would be your best bet, other than that whoever has a broaching machine will work the price of the tooling and fixturing into the quote and that is gonna push the price upwards. Especially if this is just for 10 parts. We have broaching machines here where I work and the broaches are not cheap. I'm curious though is it a press fit for the spline? The reason that I am asking is because if you could live with a radius instead of sharp corners you could probably put the spline in there yourself with an endmill and save yourself the outside processing.
See picture below, if you could have something like this then a .200 endmill and 4th axis capabilities would be all you need.

[timmydabull]

Makinoman,it is not a press fit more of a transmission shaft,the loadis against the face of the spline and not the radius.

i was thinking along those lines as well,i think i will try it.

thanks for all the advice guys

if all else fails maybe i can edm some tool steel to make a form to square the corners in a press,after machining.

[peter@slater]

This form is too large for rotary broaching. Once I got the CAD file open, it looks like the tooth height is about .080. The maximum tooth height we recommend for rotary broaching a spline is about .030, and that's with ideal depth, material and thrust.

[timmydabull]

Peter i received your email,thank you for taking the time to look at our file,turns out sometimes the obvious solution is the simplest one,as makinoman pointed out it will work out nicely to extend the radius on the outside root diameter of the part.

1 operation in house.

thank you
tim


ps i have been in the mindset as a consumer for so long that i always think first "where can i find this" that i sometimes forget i need to be in the frame of mind "how do i make this with what i have available"

[timmydabull]

Makinoman,that geometry that you suggested worked mint.

thank you for your assistance.

[makinoman]

Originally Posted by timmydabull Makinoman,that geometry that you suggested worked mint. thank you for your assistance.

Hey not a problem, glad I could help.