forgeing splines using a axle and press

[muddstopper]

I need to put some splines in a piece of 1/2flat plate. I know there are a thousand ways to do this, but I dont have any of those tools. So my question is, if I put the piece of flat plate in a forge and heat it and then use a press to push the plate over the splined axle stub, or axle stub thru the plate, what am I going to tear up. The purpose of the flat plate is to make a lever to turn the axle in the hub. 180* of rotation is all I am after. The lever will be pushed with a small hyd cyl. I dont want to just weld the plate to the axle because I wouldnt be able to remove the axle if the need arises later. I am hopeing the axle splines will act like a broach as they pass thru the plate metal. The fact that as the metal cools should make a super tight press fit would be a bonus. Should I grind the spline end flat so it would cut as it passes thru the plate metal, or just use brute force to press the axle thru the plate and let the melted metal form its own splines.

 

[RNeumann]

Broaching isn’t typically done with heat. I’m guessing you are going to make a senior project that doesn’t yield the desired results.

If I needed to make that tool I’d be finding whatever the axle went into- hub, differential etc. Then I’d get one of those and add a handle or whatever else to I could rotate that axle.

 

[WranglerX]

I would put a sleeve or "hub" on axle, attach sleeve/hub to axle with through bolt or set screws and weld arm to sleeve... Thusly eliminating welding arm directly on axle or trying to broach splines...

Dale

 

[muddstopper]

While it would be preferable to just find the rearend and steal a spider gear the axle came out of. I dont have a clue as what to look for. The axle came out of a tube assembly without the centersection still attached. Its old, probably 60's something dual wheel truck. I dont know if its chevy, ford or dodge, might even be a old international.

As or broaching, I dont have the tools for it, which is why I am considering trying to forge. More of a swage attempt than broach.
The purpose of this project is to make a small boom for loading wood on my trailer. I have the axle tube, axle and hub assembly. My plans are to mount the boom with a atv winch to pick up large rounds and small logs to place on the trailer. I have a multi-spool solenoid control valve that I will be connecting to my dump trailer hyd pump in the place of the current single spool valve. The boom will have a small hyd cyl to raise and lower the boom and I wish to attach a couple of small cyl's to the lower end of the axle to give me 180* of rotation. Now I could just simply weld the attachment arm to the end of the axle, but then if the bearings or hub ever needs worked on, I would have no way to pull the axle unless I take a torch to it.

 

[jmc]

Sounds like a great use for a truck axle. A pic of the spline with a scale for comparison would help. A full spline is overkill for your low torque app so maybe a precise hole thru your bar with some improvised interference with a spline tooth or two would be easier.

 

[Big Barn]

Why not just cut or grind the end of the axle stub square? It would then be easy to cut a matching square hole in your plate.

 

[muddstopper]

axle is approx 1 3/8 dia and 1 1/4 long. It sticks out the end of the tube about 3 inches, more than enough to attach a swing arm.

 

[muddstopper]

Why not just cut or grind the end of the axle stub square? It would then be easy to cut a matching square hole in your plate.

I thought about doing that, but not until after I started this thread, and may do that yet. I now just need to satisfy my curiousity about doing it the way I suggested.

 

[Big Barn]

I thought about doing that, but not until after I started this thread, and may do that yet. I now just need to satisfy my curiousity about doing it the way I suggested.

In that case cut a 1” D hole in the flat bar you plan to use for a handle. . Cut an 1.5 “+ hole in another thick piece of flat bar to act as a die. Grind a bit of a taper on the axle stub.

Heat bar with 1”D hole, place on top of other bar with larger hole and push axle through..

 

[ericm979]

If it's mild steel plate why not just hand file the splines in? Marking it out and using a good file it would not take long to rough it out. How long it takes to finish depends on how accurate you want your splines.

 

[jmc]

Can't see how many teeth.

Here's a link to specs on a 1 3/8" OD with 20 teeth. Yours is probably a standard spline and if you can identify it, you might find an inexpensive female component that is off the shelf at Graingers, Bearings Incorporated, or McMaster-Carr type of businesses.

GrabCAD

 

[flyerdan]

What you might consider is to make the broached pieces out of .250". Make about 4 of them just big enough for the splines, grind the dross off so they lay flat, sandwich them on the axle and tack. Center your .500" bar between and stitch it up.
Using thinner material makes it easier to punch the splines without buggering up the axle end, and stacking several gives more contact area so it shouldn't waller out later on.

 

[downsizingnow48]

Shafts with keyways and set screws are common and can be bought or made. And transmit a lot of power. Me, I would throw away the axle and find an easier thing to make.

 

[muddstopper]

If it's mild steel plate why not just hand file the splines in? Marking it out and using a good file it would not take long to rough it out. How long it takes to finish depends on how accurate you want your splines.

No plans to do that much filing, ever. I know it would work, but I aint that dedicated.

 

[downsizingnow48]

Another way to do this is to weld your arm to a 4 inch square piece of 3/8 plate, then bolt that to the thing that is supposed to rotate.

 

[muddstopper]

Shafts with keyways and set screws are common and can be bought or made. And transmit a lot of power. Me, I would throw away the axle and find an easier thing to make.

Well, I could cut the cap off the axle and throw the shaft away. then find a torsion bar out of a chevy truck and weld to the cap. Then I could cut a turning arm and attach to the torsion shaft. Attach my cylinders and have a boom with double bearings with power swing, hyd lift and a winch. Wait, that sounds like more work than just attaching a turning arm to my current axle. a axle that is proven to withstand a lot of torque

 

[downsizingnow48]

There is at least two ways to think about this. One is, I have an axle, what can I do with it, Another is, I have a mechanical problem, how can I efficiently solve it. It is possible but unlikely that the same answer will work for both questions.

 

[Big Barn]

You could have done it some way in the time it took you to type. Lol.
I like flyerdan’s idea.

Don’t make us come down there and do it for you.! You won’t be impressed with the beer bill.

 

[muddstopper]

Couldnt do it today, to busy playing with the new great grand baby. Had 5 generations over taking pictures. I know I am making excuses, but I was just dieing to do a little bragging.:cloud9:

 

[otlski]

You could have done it some way in the time it took you to type. Lol.
I like flyerdan’s idea.

Don’t make us come down there and do it for you.! You won’t be impressed with the beer bill.

Come on now. It is not like its a rounded drain plug. We can give him a few days!