Kenneth
   Did a little more study of splines and find that 24
   pitch is standard. That dictates a shaft diameter of
   1.125 with 27 teeth or 1.25 with 30 teeth. Do you
   think it feasible to shape internal splines in lobes
   using EDM to minimize distortion and stress? Also did
   a quick calc of torsion and find a 1" shaft with
   active length of 8" will windup about 1 deg under
   500#' torque. Don't know what's acceptable or if I
   analyzed correctly. What do you think.
   regards, Robert

Robert,
You are correct, I don't believe you would ever have success broaching a
spline. I personally think persuing this method would be folly. By the
time you have made the structure tight enough to be workable it would be
cheaper to turn and grind a shaft using a conventional method! The fact
is that the e-shaft is a rather simple setup. It requires that someone
with the proper dimensions go to someone with a crank lathe and grinder
and pony up to get one made. FWIW
Bill Jepson


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