How to Cut Axle Splines on a SAJO Indexing Head

To cut 22 splines requires 1 full turn and 81 holes on the 99 hole ring. The math works out to be 40/22 = 1 18/22 = 1 9/11. Find a ring on the index head that is a multiple of 11 - 99 in my case. So 11 needs to be multiplied by 9 as well as 9, which equals 81. That's how you get 1 full turn plus 81 holes on the 99 hole ring.
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[@bulletproofpepper2]

Awesome and a snap ring grove, you ready for whatever’s next! Thanks for sharing.

[@glassglowz]

Glad you enjoyed the video!

[@KuehlEngineering]

Nice Job! I dig your channel!! I don't have much content right now, but am going after a similar niche. I race dirt circle track cars, so I know we can relate with constantly building parts for our hotrods!

[@glassglowz]

Thanks buddy! I'll check it out.

[@drevil2783]

I always wondered how they cut splines. Now i do. Thanks👍👌👏👊

[@glassglowz]

Well this is the home shop method. Production uses different cutters. Thanks for watching!

[@romakayak]

My boat's transmission output shaft has worn splines and there are no more shafts in production. Is it possible to weld up the worn splines then re cut to original spec?

[@culmalachie]

Mmm.... and now the heat treatment... Oh, I'll have to find a good Index head too.Thanks forthe show Slàinte Mhath

[@glassglowz]

I sent them out and had them hardened to RC45. Still going strong today! Thanks for watching.

[@fredrezfield1629]

canadian guy cutting with a canadian made machine it can't get any more canadian than that

[@glassglowz]

True eh!

[@azentioced9]

lovely job wish i had one of those machines and knew how to work it !

[@glassglowz]

Ah man, they're great!

[@repalmore]

When I'm doing a repeated measured depth or movement, I zero my DRO at the stop point that way I don't have to remember a number at the stop point. Helps compensate for my ADD.

[@glassglowz]

That would have been a much better idea than what I did. Thanks for the tip.

[@toyota4x4canadaguy]

Nice Ontario plate. Hello from North Bay.

[@glassglowz]

haha! well hello there neighbour :) Thanks for watching!

[@TheMetalButcher]

Nice setup. Your excello is a cat 30? I always thought it was smaller than a bridgeport.

[@glassglowz]

It's a Kwik Switch 300. Slightly larger than a Bridgeport. Thanks for watching!

[@daveprototype6079]

Great job. New subscriber Cheers

[@glassglowz]

Thanks for the support!

[@ForrestFab]

hi mate great video, was just wondering what the bore size is on that indexing head, as in what the largest material size you can fit through it, i need one a similar size but having trouble finding something like that in australia

[@glassglowz]

It's 1.8" - not sure the brand though.

[@mrgtir]

HI, how many passes did u make per spline cut to get to correct depth. do you have and speeds and feeds info? i just dulled my cutter in 4140. i think i was running it to fast. you cut all the splines without dulling your cutter? (novice here) thanks.

[@glassglowz]

I did the full cut in one pass... can't recall how deep the cut was right now. I was turning it real slow, maybe somewhere around 100 rpm and the feed was very slow as well. Was you material annealed or heat treated? You need to ask the metal shop for the annealed stuff otherwise you'll never cut through the heat treated material. Hope that helps and thanks for watching!

[@davernon]

Awesome !

[@yamama8888888]

Hi guys, I have a noob question. I am making some axle spline conversion stubs and I need to have my machine shop cut the same spline that is on my Honda d16 inner cv joint. I wanted to know is there any way to specify this correctly. Right now im just giving the existing part to them and saying "copy that pls". Are all of them 90 degree? Thanks in advance

[@glassglowz]

Sorry bud, but I really can't help with that. I had a diagram from the CV manufacturer so it was easy for me! Thanks for watching.

[@teamchoko1]

was there any flame or case harding done post cutting splines?

[@glassglowz]

I sent them out to a shop and had them hardened to RC 45.

[@increw1656]

i have one question... its possible to make 16 splines to 19 splines for moped rim?

[@glassglowz]

I'm sure it's possible if you have a diving head and the correct plate. You'd need to sit down and work though the math first.

[@rowycoracing]

Cutting splines and gears is always fun. Nice work! What material are using for the axle stock?

[@glassglowz]

The first few cuts are always nerve racking! I'm using 4340 annealed then sending out to be heat treated to RC 45. Thanks for watching!

[@orlandotvvlog8325]

Can you show how to solve that pls i want to know​@@glassglowz

[@glassglowz]

@@orlandotvvlog8325 pick up a machinist hand book. That will describe it better than I ever could.

[@forrestwhittington5227]

What powerhead are you using to autofeed?

[@glassglowz]

It's called Align

[@Mrdubomb]

Nice set-up, When you re-spline axles do they need to be re-heat treated?

[@glassglowz]

I'm not sure. I've never performed a re-spline.

[@IceStone69]

Beautiful

[@glassglowz]

Thanks buddy!

[@gearhead5968]

What about fillet radius in bottom of spline ?

[@glassglowz]

You won't get that with this cutter.

[@backwardsmachining7526]

I didn't realize that was how splines were cut? For some reason I thought they had a flat spot on them unless it's different for cars? There's pretty cool because I have that cutter and never knew what it was for lol.

[@glassglowz]

I think they use a different method in a production environment. Thanks for watching!

[@DANMALaGUTI11]

I used to work at a factory that produced gearboxes for larger applications such as oil and gas, marine and power generation industry. All our splines where made using processes called gear grinding, shaving and hobbing. The gears would then be hardened in a process called gas nitriding. Hope this helps give you an idea. :)

[@hstands4hooligan]

Splines are usually rolled in a production environment. Much stronger as they compress the shaft versus just a cut

[@petermoale2116]

Hello Mate, How did you figure the depth of cut ? Thanks.

[@glassglowz]

I had a schematic of the CV joint which showed the depth.

[@artcallaghan1262]

Great video. Can you send a link for the cutter.

[@glassglowz]

Thanks! I bought this thing years ago and can't remember exactly where from. It was something like this though www.globalindustrial.ca/p/90-hss-tmx-double-angle-shank-cutter-3-4-inch-dia-x-3-16-inch-cutter-width-x-2-3-8-inch-oal?ref=5

[@dragomirionut5992]

Could someone help me with the dimensional chart for 90 degree splines?

[@glassglowz]

I think you'd find more luck on a forum like www.practicalmachinist.com/

[@yashpatil2041]

Wow great! What is the exact name for this cutting process?

[@glassglowz]

It goes by Indexing or Dividing.

[@briannotafan3368]

still wondering how mass production is done

[@glassglowz]

CNC machines with carbide tooling is my guess.

[@tylergibson7226]

where did you get that cutter.

[@glassglowz]

I ordered it off amazon

[@AboutTheBuild]

Good stuff

[@glassglowz]

Thanks buddy!

[@user-yomero]

name saw cutter?

[@glassglowz]

It's a 90 deg double angle shank cutter. www.kbctools.ca/products/CUTTING%20TOOLS/END%20MILLS/ANGLE%20@@26%20DOVETAIL%20CUTTERS/2241.aspx

[@chooboflex8154]

what this type steel?

[@glassglowz]

4340

[@davidgould8622]

What model indexing head ?

[@glassglowz]

It's a SAJO index head. That's all I know about it. Thanks for watching!

[@fredrezfield1629]

that tool by the way is a double angle chamfer cutter i am surprised it did the trick ? how did you identify the spline ? do you use a gear caliper? a gear tooth gage?

[@glassglowz]

I had a schematic drawing of the inner spline of the CV joint which showed the angle, depth, etc.

[@fredrezfield1629]

@@glassglowz i tried this it was utter failure so do you go back and do an extra pass after you completed the circle??

[@fredrezfield1629]

cause i have a carbide versionof your tool too although 8mm diameter only its called a twin chamfer

[@glassglowz]

@@fredrezfield1629 if I remember correctly, I cut the full depth in a single pass. The steel was not hardened when I cut the splines. I sent them out for hardening after.

[@fredrezfield1629]

@@glassglowz no i dont' care about that i want to achieve the shape whats the diameter of your cutter? and how thick? thanks

[@TimothyGambino9085]

That cutter is for a straight spline .. Nowadays every spline is involuted That spline won’t hold up

[@iEatSoggyBagels]

Are we ever going to see the Challenger again?

[@glassglowz]

Later this summer!!

[@iEatSoggyBagels]

Cool! Thanks

[@futurepilot6749]

Very nice

[@glassglowz]

Thanks buddy!

[@erik....]

Why did that doublesided endmill make it so much easier? A normal endmill also has 90 degree corners.. All you would have to do is cut the splines at "1:30" on the axle instead of 3 o'clock.

[@glassglowz]

Wow... It never even occurred to me to use an endmill! It was easy for me to find the center of the axle... how would I go about finding 1:30?

[@erik....]

@@glassglowz Yeah that could take some creative measuring. :) Maybe only practically possible with a DRO.

[@ronwhittaker6317]

Yep bless Abomb

[@glassglowz]

Abomb does some amazing work!

[@muhammadayub3120]

Thanks😊🇵🇰🇵🇰😊

[@everydaycar3518]

Dude wya I need a part made for my mower 😂like seriously

[@franknvett]

awesome

[@glassglowz]

thanks buddy!

[@gopalthigle3174]

I need 23 spling 1inchthick 1.5 foot long axel

[@mikemraz8569]

Fits like a saddle on a sow

[@glassglowz]

WUUUTTTT?? :D Thanks for watching ;)

[@frankherring6253]

He means it fits loose. I think you have cut the spines a little too deep. Also each one of your splines has a stress riser at the end which will eventually fail. This problem can be minimized by cutting a relief for terminating the splines in. Stress risers can’t be eliminated but can be eased. Only time will tell if your shafts will fail but if they do, keep the termination relief in mind. Hardening the shafts is a good idea, but remember to have them tempered as well, so they aren’t brittle. The company that you are having harden them should be able to do this as well.Thanks for the great videos!

[@glassglowz]

@@frankherring6253 ah ok, thanks for the info!

[@gusmcgussy3299]

That's not an end mill lol ...

[@glassglowz]

LOL... what is it called then? I'm just a hobbyist over here ;) Thanks for watching!

[@JohnSmith-cc1re]

Who needs involute teeth anyhow?

[@glassglowz]

I'm not using an involute cutter... ?

[@johnbowen2963]

loooose the blareing crap music

[@glassglowz]

Sure thing buddy, just for you 😉