splines are tight in bevel gear 2

[thejackal3]

Dear all
we got a problem in axle shaft. some of the axle shafts are tight in bevel and in some bevel is not enetering.axles are induction hardened.is there any way we can repair splines which are not entering.or tight.
Regards

 

[CoryPad]

Mechanical polishing, chemical polishing, electropolishing, and isotropic surface finishing are potential techniques.

 

[Tmoose]

What do the drawings call for?

I'd investigate for the "tight" spots with dykem ( thick ) or black Sharpie ( thinnner ) etc.
To see if a little deburring is all that is required, or some significant distortion is the problem.

 

[TVP]

You might be able to heat the internal spline component to a temperature somewhat higher than its original tempering temperature so that there will be some additional dimensional change. I have done this before in a similar situation and it was successful.

 

[tbuelna]

You should first determine whether the problem is with the axle splines or the bevel gear splines. If this is a production application, you should have a set of go/no-go inspection gauges for checking both the internal and external splines. Use the gauges to check every part from the lot/batch the deficient parts came from. It won't help to rework the axle splines if the problem is with the bevel gear splines.

 

[racookpe1978]

Going with the above - you MUST fix your process requirements and process inspections and process methods: One side or the other, or BOTH, is not fitting as required.

You don't know enough now to determine if some of your bevels are too large (and won't go into properly made in-tolerance slots), some of the slots are too small (and won't allow properly made, in-tolerance bevels to fit inside deep enough), or only a few too-small slots won't let a few too-large bevels to fit in.

So MEASURE THE GROUPS of many parts and figure out what is changing. Basic root cause analysis - Don;t build an assembly without it! Then, figure out what is causing the difference in machining (tool wear, poor fit in the grinder/gear lathe, bad casting or bad bearing or bad bearing tolerance or whatever) that is causing your parts to go out of tolerance.

Or, fix the requirements and require more tightly machined accuracy: make you tolerances closer.

Now, for the short term, AFTER you have decided what the real fix will be, you can salvage some of your parts by fitting too-big bevels into assemblies with too-big-slots, and put the too-small bevels into correct-sized slots, etc. But remember, that's what caused the tremendous expense of the first mass-produced muskets and rifles: hand-fitting and hand-carving machine parts is very slow, very expensive, and means each assembly is unique and can't be repaired with nornal parts later.