GKN compatible shafts, produce a batch?

[Frank]

I'm toying with the idea of manufacturing a batch of shafts to be compatible with GKN CV joints.

Shafts would be (order of operation)

Purchase EN26 or 4340 steel
http://www.interlloy.com.au/data_sheets/high_tensile_steels/en26.html
http://www.interlloy.com.au/data_sheets/high_tensile_steels/4340.html

Annealed material
Gun drilled either 8mm or 10mm ID
Heat Treated to 36-38Rc
CNC Turned to 20mm, and polished
Splines hobbed
Shot peened at spline start point
Black Oxide Coated
Supplied with Certificate stating material and processes, and a coupon wired to the shaft (material sample). The coupon is used for Rockwell C tests.

Shafts would be for AUS and NZ teams initially.

I'm guessing AUS $250 per shaft + GST + Delivery, but they might be cheaper if enough people were interested.

If any teams are interested, please respond and include the length between flanges mating to your GKN CV's (as per drawing) http://www.uq.edu.au/fsae/shafts.jpg

Frank

http://www.uq.edu.au/fsae/shafts.jpg

[Frank]

I'm toying with the idea of manufacturing a batch of shafts to be compatible with GKN CV joints.

Shafts would be (order of operation)

Purchase EN26 or 4340 steel
http://www.interlloy.com.au/data_sheets/high_tensile_steels/en26.html
http://www.interlloy.com.au/data_sheets/high_tensile_steels/4340.html

Annealed material
Gun drilled either 8mm or 10mm ID
Heat Treated to 36-38Rc
CNC Turned to 20mm, and polished
Splines hobbed
Shot peened at spline start point
Black Oxide Coated
Supplied with Certificate stating material and processes, and a coupon wired to the shaft (material sample). The coupon is used for Rockwell C tests.

Shafts would be for AUS and NZ teams initially.

I'm guessing AUS $250 per shaft + GST + Delivery, but they might be cheaper if enough people were interested.

If any teams are interested, please respond and include the length between flanges mating to your GKN CV's (as per drawing) http://www.uq.edu.au/fsae/shafts.jpg

Frank

http://www.uq.edu.au/fsae/shafts.jpg

[Frank]

the shafts would be a "one size fits all" WRT the length. Cut spline down to suit your specific application

looking to produce shafts in january

[Scotty]

It is a happy coincidence that the small (86mm)GKN/Lobro CV joint has the same inside spline as does the small tri-pod so commonly used in FSAE.So if you have the 20 spline halfshafts , they will work with either the tri-pod or with the CV joint.

[Frank]

Scott,

who is the small tripod centre made by?

I havn't measured this spline yet, it's SAE? 37.5deg?

[Scotty]

Frank,

The pressure angle for the splines is 45 degrees. The format is that of a serration, flat sided rather than involute. It can be made with a vertical mill with an indexing head. The cutter should118 degree to in order to accommodate the 18 degrees between splines.

The tripods were originally manufactured by GKN, but we have been unable to obtain sufficient quantities of the tripod from them recently. Therefore in January of 2004 we began manufacture of them ourselves. To be sure of quality, we have tested both the GKN and our unit to failure. The original GKN tripod failed at 1380 ft-lb (1935 nm) and ours failed at 1700 ft-lb (2380 nm). The drawing for the tripod can be found at http://www.taylor-race.com/pdf/tripod.pdf

The small 86mm Lobro CV joints as shown in your drawing above are still available, and as I mentioned above, has the same spline.