Making keyways in gear blanks. if you don't have all the big cutters.

[Captainleeward]

So I needed to make key ways in these gear blanks for my 9X20 Lathe. Some years ago I made a slot maker that you put on the lathe where the tool post goes it has a square cutting tool in a bar So I set it up on the lathe and after putting the gear blank in the chuck I realized that this would take a week of going back and forth cutting on this keyway.

So I set the gear blank up on the drill press and drilled a small hole the same width as the width of the slot then used my key way cutter to get good results as you can see in the photos there is a small round at the top but is very small no big deal.

This is my tip of the week for you enjoy. a small square file is handy to.

http://www.homemadetools.net/forum/a...044d1413226200



http://www.homemadetools.net/forum/a...044d1413226200

[Toolmaker51]

re Your Keyways, Captainleeward...the arc shouldn't cause any issue. The depth at corner and width of slot are the real 'make or break' considerations. Width of course is a backlash type of action; hammering away at whatever is softer, wheel, key, or shaft. Depth is what keeps the key in place for greatest engagement of shaft and wheel.
Getting excess material out of the way is a challenge sometimes. Theory is fine, but can affect the final result, usually because there isn't enough to work the next cutter well. Drilling the material center is better idea than trying to drill small holes inboard of corners. Did you cut keyways in the lathe or by shaper vertically in the drill. Good too; but how did you regulate movement and depth of cut?

[Captainleeward]

Hello,Toolmaker51
The key ways were cut on the lathe cross slide after the hole was drilled on the mill. then I fit the key to the key way with a small square file.
I regulated movement and depth of cut by the cross slide until the depth was achieved.
I shall keep in mind your backlash type of action statement. Thanks for your comments and observations. :O)

P.S. This my first attempt at key ways.

[Toolmaker51]

My pleasure sir, and compliments on first of anything, especially keyways. An incalculable number of mechanisms count on them to drive components and operate; with a broad variety of keyway types as well.
I'll prepare an illustration and post here. A rainy Sunday, why not?