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  1. #1
    sconisbee is offline Aluminum
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    Default Keyway cutting tips needed

    what is the best way to cut 2 symmetrical 6mm key ways on two sides of a tapered section of shaft. This would be on a vertical manual mill.

    I know its a simple question but its not something i have come across before normally theres only 1 key on the tapered sections. If it helps, overall shaft length is 210mm and its an 8 degree taper on one end with a threaded section on the very end.

    thanks

  2. #2
    Mark McGrath is offline Diamond
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    I would use a dividing head with the job in the chuck.Swing up to the correct angle and mill first keyway.Index 180 deg and mill second one.
    Mark.

    Was that a trick question?

  3. #3
    sconisbee is offline Aluminum
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    Quote Originally Posted by Mark McGrath View Post
    Was that a trick question?

    Nope not a trick question, apparently just having one of those days. I'd completely forgotten about the dividing head and i only serviced the bloody thing yesterday.. Pretty sure im loosing my marbles sorry

  4. #4
    Limy Sami is online now Diamond
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    Quote Originally Posted by sconisbee View Post
    Nope not a trick question, apparently just having one of those days. I'd completely forgotten about the dividing head and i only serviced the bloody thing yesterday.. Pretty sure im loosing my marbles sorry
    They're probably where mine are.

  5. #5
    gbent's Avatar
    gbent is online now Diamond
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    How would you hold the shaft if you were only going to cut 1 keyseat? Are you going to use an endmill or a woodruff style cutter? That gives some idea of how to approach the problem.

    For simple 180 degree indexing, such as cutting opposing keyseats, I often clamp an extra vee block to the shaft. You can then indicate the base of the vee block, or align it with a square on the mill table. For a woodruff type keyseat cutter you may be able to clamp the shaft in a vise and turn the vise on the table to align the keyseat to the mill travel. Then you have to decide whether to turn the shaft or swivel the vise to cut the second keyseat.

    A dividing head may well be the best way to do the job, but my dividing heads are both large units. For a one off job I can take the long way around and have less time in the work than if I have to install and remove a dividing head.

  6. #6
    sconisbee is offline Aluminum
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    Ironically my dividing head is currently sitting on the mill table, just needs bolting down. I've been so off and lost in lathe land these last couple of weeks that anything mill related seems way too complicated cause its more than 2 axis' to worry about I only got a little Cornish brain ya'll know

    Still I also like the idea of the extra v-block.

    Sami, I'll have your marbles DHL'ed to you as soon as i find them, assuming they are in the same place

  7. #7
    Limy Sami is online now Diamond
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    Ta! ............

  8. #8
    FlatBeltBob is offline Stainless
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    If you have a shaft that is too long to use a dividing head , I have tack welded a small metal
    bar on the end of the shaft , so I can set a level on it .
    Then I rotate the shaft 180 and set the level on the other side of the block .
    I have one square head with a level that I hide away for these special jobs .
    You would be amazed how accurate you can get by just bumping the bubble to the line .
    Sometimes I need to saw longer pipes with an angle at each end that need to be oriented in the same plane . ( like for hand railings ) . I made up a tool using a large ViseGrip pipe pliers that I welded a flat bar on the side of the handle. Then using the level , I index the pipe in the vise to set the first cut 'level' . Then I flip the pipe over and set the 2nd angle as described above .
    FBB

  9. #9
    Toms Wheels's Avatar
    Toms Wheels is offline Titanium
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    Default

    I'd use a keyway cutter, clamp the shaft in vee blocks on the table, indicate the taper to the X axis, cut the keyway, then reset the blocks or you could rotate the shaft using the cutter as a stop in the groove, then cut the second keyway.

  10. #10
    Mark McGrath is offline Diamond
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    Talking

    Quote Originally Posted by sconisbee View Post
    I only got a little Cornish brain ya'll know:

    Sami, I'll have your marbles DHL'ed to you as soon as i find them, assuming they are in the same place
    If you had said you were Cornish I wouldn`t have asked if it was a trick question.

    If you send the marbles DHL,you`ll both have lost them forever.The worst parcel delivery firm in the UK.

    Mark.

  11. #11
    SBAER is offline Hot Rolled
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    If the shaft can be held in a collet, I would mount it in a square or hex collet holder, make one keyway and flip the collet holder it to do the other side

  12. #12
    locoguy is offline Hot Rolled
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    Default

    Are the KW's straight with the length of the shaft, or ramped with the taper section?

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