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

Rolf and Bill
Thanks for the comments. Glad to get expert opinions
on this. I guess if this were a viable approach it
would already have been done.
regards, Robert


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