Quote:
Originally Posted by JesseK
This is all great info -- the kids did an offseason drive train design on their own from scratch (sans help), and if they went down the hex-shaft route I was going to buy the team a 1/2" hex broach for Christmas.
How long does it take to broach a hex through a typical aluminum sprocket (5/8" wide)? We have both a 3-ton press and a (decent) manual lathe available.
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I would recommend against using the lathe if at all possible. Depending on the size of your lathe and the force you're applying to broach your part you could damage the spindle bearings.
We've winged it a couple times when broaching small parts and stuck the broach in the spindle of our mill and pressed it through with the knee, when we wanted to make sure it was absolutely perfectly perpendicular, but it's really a very bad idea. You never want to apply axial force to bearings that aren't spinning.