Manufacturing design of plain milling technology of spline shaft by formed disc-type milling cutter

Abstract The spline fittings are widely used in different mechanical constructions where high load transmission is required from a shaft to a spline plate or a tooth gear or other internal cylindrical element. In many cases a key joint connection can not bear the load that we want to transform. In this case the application of double key could give solution. But sometimes it does not give solution due to the high load that is why spline fitting should be used. This publication focuses for the manufacturing of the spline shaft with plain milling technology. The type of the tool is a formed disc type milling cutter. Since more splines are around the perimeter of the shaft the repetition of the milling process is needed in the function of the number of the splines. All of the manufacturing parameters will be determined that are needed for a complex technological analysis such as cutting forces, machining times, speeds, etc. The chip volume will be approximated by volume constancy since the separated chip volume is a quite complex geometric body. I will prescribe initial technological parameters and define existing shaft geometries for which I will determine the technological parameters to show and analyze the correlations between the technological parameters and the variable for each shaft.