I made mine out of and old live centre, as they were advertised for silly money (£400). Cut the Morse off and welded it back to get the wobble, which is made up of offset and angle. The end of the tool is central with a ~5deg angle. Not pretty, but neither am I. Bought cheap set of allen keys, cut them down and ground them up. Rough but works well. Don't have any splined broaches.
Thanks for finally revealing how you made that second part.
Just your perfectly normal average run of the mill job then JohnnyCutting them is Pi$$ easy. The bit that takes a lot of figuring out is the diameters that will work with a tooth profile that you still need to develop. Spent more time drawing it than machining it. For those wanting to know,they are shockabsorbers from a Panzer IV that belongs to the King of Jordan…All I had to go on was the very rusty remains of an original where the splines were very much non existent,and a couple of photos of original drawings with no dimensions
Cutting them is Pi$$ easy. The bit that takes a lot of figuring out is the diameters that will work with a tooth profile that you still need to develop. Spent more time drawing it than machining it. For those wanting to know,they are shockabsorbers from a Panzer IV that belongs to the King of Jordan…All I had to go on was the very rusty remains of an original where the splines were very much non existent,and a couple of photos of original drawings with no dimensions
Internal splines? Is that to make the broach?
This is the geometry I used. Not saying it's professionally correct, but works for me. Point for geometry only. The point was replaced with a hollow to take broach and grub screw (which I never bothered with). Clearance ground on sides of hex broach and concave dome (rake) produced in end with ball end tungsten burr.
Quite correct about broach limitaions, also producing a splined (accurate) broach would be the most tedious, without having the mating part at hand. I could do it on the shaper, but the Elliot 10M's table is bit small for the dividing head and chuck, although RobCox has done it on his for the gear cutter, which is basically a spline. I use it for internal keyways (rarely) without issue,Yes, anyone can cut splines
Wobble broaching has its limitations in that the depth you can cut to isn’t as great as many people would like to believe. You run into clearance issues at the back of the tool. I made a proper wobble broach holder a couple of years back for the Cnc lathe. Once you get your head around centering it ,it works pretty well.
Broaching on the Cnc lathe is quite easy to do,once you have figured out how to code it. I find it easier to write a program that calls a subroutine. Bit of messing around to design the tools and get them made,and seeing people generally don’t want to pay for your time,it’s not something I do often,apart for customers that understand this. Loads of ex spurts out there that say it only takes five Minutes. Well, take it to them then….Oh, let me guess, they are too busy at the moment. By the time you have designed the tool and holder,made it,programmed it ,cut a test piece and made your couple of splines,you have spent a day on it. Spread this cost over 200 parts and it’s minimal. Spread that over two and it’s not…..
This was a fun job. Tapered splines.27mm dia one end, 28mm dia the other. Did both internal and external splines for the customer. Funnily enough, R and N quoted on this job too, but weren’t competitive with the price that time.
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www.aliexpress.com
They seem an interesting ideaA bit late to this, but I have just seen:
Morse Taper / Straight sShank Internal Hexagon Rotary Broaching Tools CX08 CX16 Square Head Punching Rolling Burnishing Cutter - AliExpress 1420
Smarter Shopping, Better Living! Aliexpress.com
It is worth looking at their main site: https://sannotools.aliexpress.com/store/3621123 The keyway-cutting tool with screw on insert looks a good idea.
Hmmm, will take a look at that, spent ages the other night form grinding a tool steel cutter for my notcher -'if I made a holder, I could buy the tips....
Hmmm, inserts and holders, a minefield I haven't found my way throgh yet...Unfortunately everyone seems to change their inserts slightly so it only fits their Holders
