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Cutting internal splines

M

Mtjohnso

Member
The problem I am dealing with is on a orphan dozer but the problem is generic.
On the drive sprocket for the dozer there are splines on the drive shaft but none inside of the drive sprocket that slides onto the splines.
Somehow they got stripped out. So what to do?
The dozer is made by Windolph in Portland Oregon in the 50s. Not a lot made and I expect the probability of finding another drive sprocket is minimal.
So my thought is to have a machine shop cut out the inner 2 to 3 inches of the hub of the drive sprocket and then have the machine shop turn a new hub
with new splines cut into the internal part of the hub. Then weld the new hub into the old sprocket. I would also assume that the new hub would need to be hardened to make the splines hold up.
How do they cut the internal splines on a hub? I understand how they do it on a drive shaft.
Thoughts? Is this way out in left field? What would you do besides send the whole thing to the recycle. Would really like to fix this correctly.
Marvin
 
I've run into problems like that on some of the old cranes Dad and I used to work on. In those cases we were able to take the shaft and have two keyways cut 180 degrees apart, and then have two keyways broached on the mating part, also 180 degrees apart, to match. Done right, the keys will carry just as much load at the splines, and the machine work involved is a lot less involved. Might be worth a shot in your situation too.
 
Internal splines are done with a broach that is specific to that spline. You would have to find a broach ($$$$) so probably not practical.
 
You might look around your area for a job shop that has an EDM wire cutter. At work we occasionally have internal splines wire cut for prototype parts by an outside shop if we don't have the necessary broach rod available.
 
What size spline is it? You might be able to buy a hub or pulley with the correct size spline and adapt it. Try a Google search on the size.

Second choice would be wire EDM.

Another option would be laminating, or stacking several thinner (1/4"-1/2" thick) laser cut discs to get to the thickness desired.
 
As far as the actual cutting of the splines, any shop with a shaper and index wheel can do that. The problem will be finding a shop that still knows how to use a shaper. Piece of cake for a shaper.
 
Give gear products in melrose park illinois a call. They can reverse engineer a new gear for you.
 
To me that sounds the best way. And there are tools to cut the internal keyway that only require a hammer to do it. Last year Amish friend cut one for me on a repair job and I watched him do it.
 
Take to a heavy equipment service guy with a bushing welder, build up missing material, put on shaper and cut new splines.

Option two is have a new splined slug made and bore slightly undersize hole in sprocket, press then weld the slug in place.
 
If objective is to maintain originality: google splined sleeves (numerous hits), when you find one that matches your application, bore center out of sprocket and press/weld sleeve in place (maintaining concentricity). Second option would be to key it, third to weld it. Good luck with the Windolph, not many around.
For example
 

There's an outfit down in town that has a computer controlled water jet that would do the job, I've seen several examples of gears (both internal and external) that they've done and the precision of the cuts is amazing :shock:
 

There's an outfit down in town that has a computer controlled water jet that would do the job, I've seen several examples of gears (both internal and external) that they've done and the precision of the cuts is amazing :shock:
 
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