They have a dia of 1.900" and a .750 shank they take three TGP321 inserts and do to the clamp holder they can use carbide,cermet or ceramic inserts. with a set of ceramic inserts one can get up to 10 shafts before having to index. they come with three coated carbide inserts and the wrench.

There $150 and $12 shipping

Duffy Dieu
D.D.Machine
3686 nw canyon st
Poulsbo WA
98370
(360)649-4465

pic #2

They were designed with the insert sticking out the bottem about .050 so one can touch off on the top of the shaft and then come down .312 (5/16) plus half the dia of the shaft to get on center line,,, makes it real fast and easy to set up.

I thought you were BSing when you posted about these in another thread, nice job.
The hard part is finding a divider head with the relative index possitions, besides a rotary table and calculator.
Can I suggest a similar tool for TRE reaming using inserts, I was thinking of making one myself.
Again, nice work on that little tool.

I dont think a TRE reamer would work made with carbide inserts.. they would try and chater to mutch,,, HSS is mutch better for that. I`m working on doing a kit for lining up D44, D60 and 14 bolts now,,, it well be about like most the others ,, two donuts for the chunk and some cones and donuts for the outers,,, But it well be a LOT cheaper than the ones I have found,,, Its great having a 25 HP CNC turning center in the shop.. but today well be spent running a batch of dimple dies off. you well see them on hear in a few weeks ,,, they have to go to the heat treaters first .

some of the other thangs on the drawing board are

bearing puller (diff bearings)
high steer arms,, D44-D60 and toy
brake kits for rockwells
and some I`m keeping under raps for now.
:D


P.S. is there any interest in doing a 45* cutter for 14 Bolt or toy axles? it would take all the math out of using a end mill. and be cheaper to use.

Originally posted by d.d.machine
I dont think a TRE reamer would work made with carbide inserts.. they would try and chater to mutch,,, HSS is mutch better for that. I`m working on doing a kit for lining up D44, D60 and 14 bolts now,,, it well be about like most the others ,, two donuts for the chunk and some cones and donuts for the outers,,, But it well be a LOT cheaper than the ones I have found,,, Its great having a 25 HP CNC turning center in the shop..

Yea, you're right, the HSS would cut easier.
What size bar will you be using with the axle jig?
I got the CNC hp covered, just not the C axis controls, old school indexable Hardinge 42mm slantbeds. Waiting for business to pick up to order a new Daewoo Puma 240, then some fun will begin.

bar size ,,, the one I use is a 1.250" and it works good,,

poma`s are nice but after geting a new mori seiki 3 years ago I`m spoiled...

Thangs have been slowing down hear for the last few years but now I`m going after my own products and hop to turn thangs around this year. I was mostly doing high tech chit and that type of work is DEAD right now,, I have gone from holding .0002 on parts to now seeing drawing with .062 +/- on them :mad:

Commercial tolerances are nice, especially when you work with microns all day. I wouldn't mind the MoriSeiki but it's too pricey for our small shop right now, but who knows maybe we'll find one at an auction.
The new tax incentives on new machine purchaces are sweet, buy a new machine for up to a $100K and it depriciates 100% the first year. Last year we worked 32 hour weeks all year long, right now we're just under normal orders and back on 40 hour weeks. The dot com boom put some decent cushion in the bank for the bust.
As soon as I get a machine empty I'll be running some odds and ends, enough to get a yellow star.
Good Luck with business.

Originally posted by d.d.machine
I have gone from holding .0002 on parts to now seeing drawing with .062 +/- on them :mad:

I am not a machinist, but isn't that kind of an insult for a machinist to see on a drawing?

I couldn't even call that a tolerance. I deal with .000* all day long. Too funny...

Originally posted by Eric


I am not a machinist, but isn't that kind of an insult for a machinist to see on a drawing?

Not much of an insult when you're getting paid for it. The cycle time of a part gets dramatically faster with open tolerances.
DD's spline cutter still has some +/- .0005" for the point relationship on the insert, otherwise it would cut a screwy thrust angle. But I'm sure the gullets are wide open.

yes the shank is held to .750 to .749 Dia and I checked the TIR ( total indicated runout) on every third tool,,, the most I found was .001 ... thats more than close enought for this tool,,,, its not like the spline that it cuts is going to be off even 1/10 of that ,,,, its a angle thang :flipoff2:

and even if you wear off on the angle a little the first time you jumped on the skinny pedal you well get full contact,,,,

I had a buddy spline dana axles with a endmill that cuts 45* spline and danas use a 30* and he would break shafts and the splines never striped out,,,,, Not that I think its a good way to do it ,,,, but I`m just trying to make the point that splines are not rocket science. thrue the years I have cut splines on horizontal mills , vert mills, mill/drills, and do a lot on shapers.

do you also have broaches?

and if so what sizes do you have between .7 and 1.25 in

and what would be the cost on 2 broaches and a spline cutter

trd I don`t now what you mean by broaches? .7 to 1.25 throws me off.

But all I`m making now is spline cutters and axle shims ,,, I well have set up bars for D44, D60, 14 B in a few weeks. Hop to get the dimple dies over to the heat treaters mid week.

i want to be able to cut male and female splines. So i would need a broach for the female splines (right??)

.7"-1.25"

With his spline cutter you have the capability of making a broach in tool steel and tempering it to a certain hardness depending on the use of a desired broach. If you want to broach 30 splines at a minor diameter of .94" and a major of 1.0" you'd need to make a progressive broach, one that steps up diameters per set of broaching edges. It would be a very long broach too with many steps, it could be done but it would take a long time to make the broach and the broach's life span will be somewhat short due to the way you made it and the material used.

these would be used on gears, I am probably just going to send them out but i thought it would be nice to be able to do it my self.

Sent you a PM! ;)

WARNING,,,,,,, My hotmail is down so any of you that have sent Emails to it in the last few days I have not got them,,, Sorry
Please remail them to me at djld98370@yahoo.com
Thanks Duffy

Hello I am thinking of resplining my Spicer 60 & 44 axels, I have a Bridge Port mill "Horizonal" .I was wondering what else I would need besides your cutter to do that any Ideas.
Indexing Head??

I am very new at this so any help would be great

Correction Vertical

yes a bridgeport works great for doing them,,, You can use a dividing head or you can use bench centers and a three jaw chuck.

just mount the 3 jaw in the middle of the shaft with a crowl plate on the back of it ,,, when you make the crowl plate do it for 30 and 35 spline...

Or there is a nother way to index that works great but its hard to explain... call me if you like. shop # (360)779-2500 cell #(360)649-4465

Duffy
D.D.Machine

My spline cutter showed up today. It looks great. Thanks Duffy.

How fast are you spinning these cutters? I know you have to run carbide a lot faster than HSS. The formula for a rough guess at the cutting speed using a HSS end mill (from the class I took) was 280/diameter. That would put a HSS tool this size at around 200 rpm, give or take a few rpms. I'm guessing that I'd want to spin the spline cutter with the carbide inserts at about 4 times that speed. Is this right, or am I way off base?

cutting speeds,,,,,
The formual is surface footage ( constant) times four divided by diameter.

HSS surface footage constants

mild steel 110
tool steel 80
aluminum 300
stainless 40


carbide
mild steel 300
tool steel 200
aluminum 500+ ( balls to the wall)
stainless 120

.................
example
milling cutter with carbide 1.9" in dia
materiel axle( AKA tool steel)

constant for tool steel is 200 with carbide
so take 200 and times it by 4 then divide it by the dia of the cutter so you would get 800 RPM for a 1" dia cutter..... but this cutter is 1.9" in dia ,,,, so you take the 800 RPM`s and divide it by 1.9 = 421 RPM ..... But do to the light cut and that I use coated inserts I have been running them at 660 RPM and its working great.
>>>>>>>>>>
Now for lathe work you use the same formula but you use the DIA of the part rather than the cutter dia.

Feed formula
RPM times ( number of teeth times feed per tooth)

So 660 RPM times (3< numder of teeth> times .002 feed per tooth)

660 X .006=4 IPM AKA ( inches per min)


so you want to be around 300 to 600 RPM and have a feed of about 4" a min for this cutter. there is going to be a lot of varitables in this on how hard the shaft is,,, how ridged your machine is... how you hold the work,,, ETC
But that well get ya in the ball park.

Thanks. That's what I needed to know.

There is a new batch fresh from the VMC.

TTT

Is the price coming down running a batch that size? Are you going to be trying to sell these at the swap meet in Puyallup?

The last batch was the same size ,,, for the amount of time I have in making them and the parts I have to buy and for the shipping included the price well not change. and I have spent about 20 hours in the last month and a half on the phone talking to buyers about how to use them, I feal that $150 is a vary fair price for a custom made low volume tool that has multiple tight tolerances.
well I have yett to find a bad one I still load and check the TIR on EVERY one before it leaves the shop.
With over 20 of them out there now and not one bad word about how they work I`m happy with the design.



They well not be for sale at the swap meet this year,, I have way to mutch work to spend all day there this year. I might run up there and try and score a T400 with a 203 for my heep,,, But I have to run about 800 tool steel parts for dimple dies and work on the doubler set up . I hop to be at the heat treaters mid week.

Duffy

Hey ya probley make your money back for the tool after splining 2 sets of axles at about $90 a set.

Hey i might be interested in buying 5-10 of thoes to resell at the swap meet at my booth. I will PM you about it.

Ttt

Ttt

Hey Duffy,

Next time you spline some axles with a vertical mill, can you take some pics so I can see what parts I need to acquire to do this at home?

Thanks.

Duffy

1. Nice work!
2. does the insert used have the proper geometry (too lazy to look it up)
3. does it work for 30-31-35-40 spline axles?
4. where do i send money?
5. thats a deal at that price for a low quantity tool!
6. Keep up the good work!
7. good luck

Eric I well be doing some doubler shafts in a week or so ,, get ya some pics then.

MC this cutter is for the 30* or as some call it the 60* angle splines... there are two angles used for axles for the most part, 30* and 45*,,,

The only 45* axles I find are the toyota and the 14 bolt... dana and most other axles use the 30* cutter.

to get one you can use paypal ? my name is (dd98370@hotmail.com) or one can ship me a check

Duffy
D.D.Machine
P.O.Box 69
Poulsbo WA
98370

Shop # (360)779-2500
cell # (360)649-4465

Eric I well be doing some doubler shafts in a week or so ,, get ya some pics then. Duffy
D.D.Machine
P.O.Box 69
Poulsbo WA
98370

Shop # (360)779-2500
cell # (360)649-4465


TOP......just a reminder to get some photos. :D

Eric I well be doing some doubler shafts in a week or so ,, get ya some pics then.

Duffy
D.D.Machine


Any pics yet? :D

eric no pics yett I have done some axle shafts but had a brain fart ,,, I hop to find time to run the doubler shafts this coming week ,, I have to spend all weekend finishing up a run of pinion depth tools. and then the first part of the week well be running a load of plates for the back side of 203 cases and plates for chebby figure eight 205 inputs.

Duffy

Ttt

I know this is a dumb question, but I'm trying to learn all I can about running a mill and a lathe. This cuts splines with a vertical mill and an indexer correct? THe centerline of the shaft would be perpendicular to the cutter?

top......any pics yet?

Ttt

so can you use these to make dana axles?

~Kirk

Kirk yes there for dana shafts and any others that use a 30* contact angle..
they work on D30 thrue D80
P.S. I have some D44 to do this next week and well get some pics then ,,,
Thanks Duffy

Can you list what tools you use to set this up and cut the splines?

The female input on Dana 300s uses a 30deg contact angle right?

Yes dana 300`s use a 23 spline 30 degree input shaft... Same as scout 20 auto but with out the threads on the end,,

just turn the shaft down to 1.220 and rought cut the splines and leave about .005 a side for a finish cut .... then take a couple small drills that only touch the sides of the V and measure across them then measure a stock shaft and subtract the stock size for the just cut size and divide by 2 and that gives ya your infeed for the finish cut ... If your cutting down a doubler shaft leave it full length and spline the Vary end first to get your size and check your work ,,, then spline up to were you need it.

P.S. I do all the shaft hard ... Do not have them annealed

Duffy

Thanks, thats what I needed to know. Yeah its for a doubler. Since I'm turning down a larger case hardened output shaft to fit the D300, I should have it annealed?

PS, what would you charge to do this? I have access to the bridgeports at school, but if what you would charge is not much more than the cost of the cutter I wouldn't mind sending it out.

I don`t have time right now to do any spline work ,,,, but ORD or dutchman can do them ,,,, it should be about $100

Or try dirtybird on hear .....

P.S. If I was you I would get the cutter and learn how to do spline work well you got the chance ,,, and turn the shaft just how it is ,,, well they are hard there not to hard to turn or spline ,,,, having them annealed well screw them up... A few years ago a customer told me I had to anneal his axle shafts before I could spline them ,,, when he came back to pick them up I gave him his axles back resplined and handed him his old wheel bearing with splines cut in it to :laughing: ..... Got to like good old cermit inserts

Duffy,

Do you still have any of these availible? Let me know and I'll get you some $.

Thanks,

How deep do the splines need to be for a Dana axle (44 and 60)? I have one of your tools and finally a dividing head but wanted to make sure I don't go too deep on the spline.

Thanks
~Kirk

The calculations are in Machinery's Handbook. It's a 24/48 pitch spline, side fit. The 48 part of the pitch is a number you'd use if you were dealing with a stub pitch, but you aren't cutting a stub pitch so use 24 pitch for the calculations.

Major diameter external = (N+1)/p = (30+1)/24 = 1.292"

Minor diameter internal for 16/32 and finer = (N-2)/p = 1.167"

Depth of cut = (major diam - minor diam)/2 = .0625"

Edit: I forgot to throw this part in there. That's your depth of cut if you hit the major diameter +/- 0.0000. You need to adjust if your major dia is off. If the major diameter finishes at 1.288 you will want to cut .061" deep, for example.

measure a spline by using 2 wires that have the right dia to only touch the sides of the spline not the bottom or the top of the "V". You can get close =/- .005 with using infeed for size .. but it changes with part OD and the radius of the inserts and the rigidity of the machine ,,,, I just eye ball the first cut around ( roughing cut) then use 2 wires and a micrometer or pull out a thread mic that I have with the tips ground down just for axle splines


Just put one wire in the V at the top of the shaft and one at the bottom and then slide a rubber band over them ,,, then mic over the top of the two wires ,,,, then mic the old splines(with the same wires) and that well give you your #`s for the finish pass ,,,,

Duffy

Still selling these?

yes there good in stock. just hit paypal and they hit UPS.
Thanks Duffy
D.D.Machine

Now are those TPG321 or TGP321. Enco has a sale on the TPG321's but I wanted to know for sure what the cutter takes. Also, to PayPal you I take it that the address for that is your ddmachine@sinclair.net address. Thanks

They use TPG-321 or TPU-321 inserts... TPG are made to a IC of =/- .0005 and TPU are =/- .001 ... BFD I use what evers on sale when I need them.

Enco has TPU-321 C6 Tin coated on for $1.59 (10+) right now ..Part # DF341-9321

Paypal name is dd98370@hotmail.com <<<< NOT A GOOD EMAIL ADDRESS

Thanks Duffy

Thanks Duff. Youv got PayPal:D

I 2nd the idea of having pics of the vertical bridgeport setup!!
You should setup one of those plate things with 30/31/32/35 capabilities...
I'm under the assumption that I can use a rotary table?
I would like to cut a 31 spline shaft for my ford doubler...
31 / 360 = .08611 correct?
Havent measured anything yet, but using your forumulas posted before I can calculate the depth etc..just curious about the rotary table thing.. I cant afford an indexer and we dont have one at work...
btw im a newbie, feel free to tell me what the correct "lingo" is on that plate

your rotary table has 40/1 or a 90/1 gearing in it? on a 40/1 table you would use a 31 hole disk and do one turn and 9 holes ( 1 and 9/31)

I don`t now off the top of my head about a 90 to 1

and yes I well post some picks next time I spline, got to make some drive pucks in the next few weeks. might have to get some on doing internal splines to.

your rotary table has 40/1 or a 90/1 gearing in it? on a 40/1 table you would use a 31 hole disk and do one turn and 9 holes ( 1 and 9/31)

I don`t now off the top of my head about a 90 to 1

and yes I well post some picks next time I spline, got to make some drive pucks in the next few weeks. might have to get some on doing internal splines to.

Ttt

after you respline the axle do you get them heat treated? If so to what rockwell. Also, where do you find out what pitch you have?

Just setting up the machine today to make a new run of the spline cutter, this time I`m making the 30* (dana 30/44/60/70 ) and for the first time I well be running some 45* cutters for the ford /toyota /14 bolt guys

30* well be shipping next week. 45* the week after.

Thanks
Duffy
D.D.Machine
(360)779-2500
* still the $149 with shipping*

Duffy will you post up what tooling you are making??
R/T

These are a great product for a great price!!!! Not to mention the excellent service from Duffy!!! I have both the 30* and 45*

Hello Duff
I just sent you payment for one of the spline cutters via PayPal. I would like to purchase one of the Enco Dividing Heads like you are using could I Please get the info on the unit.
1-541-404-5783
Thanks
Richard

They have a dia of 1.900" and a .750 shank they take three TGP321 inserts and do to the clamp holder they can use carbide,cermet or ceramic inserts. with a set of ceramic inserts one can get up to 10 shafts before having to index. they come with three coated carbide inserts and the wrench.

There $150 including shipping

Duffy Dieu
D.D.Machine
3686 nw canyon st
Poulsbo WA
98370
(360)779-2500

Yes i like the looks of this. I think i will take one. Idid call you and left a mesage and PM you. Thanks Bobby.

I'd like one of each if you still have them in stock. Let me know and I'll paypal the funds. I am also interested in dimple dies...

still have 30* and 45* cutters in stock
Thanks
Duffy
D.D.Machine
(360)779-2500

still have 30* and 45* cutters in stock
Thanks
Duffy
D.D.Machine
(360)779-2500

I have to spline an output shaft from an Isuzu transmission to mimic the 23-spline output shaft on a Toyota R151F transmission. Is the 45* cutter the correct one to use? I don't know how the angle is measured to determine which cutter I need.

Thanks

They have a dia of 1.900" and a .750 shank they take three TGP321 inserts and do to the clamp holder they can use carbide,cermet or ceramic inserts. with a set of ceramic inserts one can get up to 10 shafts before having to index. they come with three coated carbide inserts and the wrench.

There $150 including shipping

Duffy Dieu
D.D.Machine
3686 nw canyon st
Poulsbo WA
98370
(360)779-2500


Hi

What inserts are used on the FORD nine inch axles shafts ( 28 and 31 splines ) to cut the spline ? would be interetsed in the tool cutter if they can take the right insert for nine inch axles.

cheers

9" use a 45* spline, same as toyota, gm10/12/14 bolt

Thanks
Duffy

9" use a 45* spline, same as toyota, gm10/12/14 bolt

Thanks
Duffy

Ok understand its at 45 degrees , but what about the radius on the end of the insert ???

Do you have a insert number ??

cheers

the 30° ones are for Dana splines correct? do you have those in stock and are they $150

Thanks
JM

Have lots in stock. Both 30* and 45*
Thanks
Duffy
D.D.Machine
(360)779-2500

I couldn't even call that a tolerance. I deal with .000* all day long. Too funny...

there good in stock.
Thanks
Duffy
D.D.Machine
(360)649-4465

Here is a video of a guy using Duffy's spline cutter. Shows a nice setup that should be easy to duplicate with a regular Bridgeport type mill.

http://www.youtube.com/watch?v=jW7M_tp6jzw

Will

good in stock, best way to reach me is my cell phone
Thanks
Duffy
D.D.Machine
(360)649-4465

Got mine today and tried it out tonight. Great product. Thanks!

Could you use this to cut spline on a 203 shaft for a 32 spline 205 doubler?

Are you still looking for someone to do internal splining?

If so pm me

yes this well work great for resplining 203 output shafts, there a 30* spline

thanks
Duffy
D.D.Machine
(360)649-4465

( I think i have a "NEW" 203 output shaft thats 32 spline, I ordered one a long time ago and never used it)

pms sent

Is the 30 degree tool still available?

Andy

Here is a video of a guy using Duffy's spline cutter. Shows a nice setup that should be easy to duplicate with a regular Bridgeport type mill.

YouTube - Cutting Dana 44 splines (http://www.youtube.com/watch?v=jW7M_tp6jzw)

Will

You could have put that shaft 3 inches further in the chuck and saved a lot a vibration. And a 1 inch thread boring bar does an excellent job cutting 30 degree splines, and most shop have one in stock.

still selling these tools? lookin to get a 30* and a 45*

I well have more in stock soon.
Thanks
Duffy
D.D.Machine
(360)649-4465

I well have more in stock soon.
Thanks
Duffy
D.D.Machine
(360)649-4465

Awesome, I'll be givin ya a call to get some ordered. :D

let us know if he answers his phone or he calls you back.this guy has good stuff but sorry customer relations i have tried for over two months to reach him and still no answer

just looked its been four months since he has been here

ok do't lhaugh at me lahough with me

what the hell does that bit cut :confused:

daaaaaa if i had read all the post i could have answer that my self

PM Sent. I would like to buy a 45 degree cutter if they are still available. Thanks.

yeah ya got more of these made yet?

still want to buy a 30* and a 45*
maybe 2 of each?

let us know, awesome product!

any updates?

pm sent. :D

I've tried to reach this guy by calling the shop, his cell, and via email. No response.......... Looks like he has a good product, but how do you get it???

I was able to get ahold of him through his ebay account about a month ago. He said he has them turned but needs to get them on the mill. Said lead time would be a few weeks; this response was dated 01-30-10. Hopefully he hasn't given up on these. If you guys hear anything, please let me know. I will definitely do the same.

I would like both a 30 and 45 degree cutter at this point, heck maybe two of each.

There back in stock
I have the 30* and 45* on the shelf
Thanks
Duffy
D.D.Machine
(360)649-4465

Received my cutters today. Wow! Awesome product. Very impressed. Thanks Duffy!

my bad i jump the gun like a dumass. he is a very nice guy answer all my q's

doesn't matter if its a good tool if the tool selling it won't answer the phone !!!!!!!!!!!!!!!!!



Just shoot him a PM. He logs on ever couple of days and will answer you. Despite being really busy, he always answered my questions and took care of my order pretty darn fast.

got my 45DEG. cutter today looks good can't wait for the super spacer to get here next week so i can make some chips lol

been trying for over a week to get ahold of you to buy another cutter no reply to p.m's no return calls whats up???????????????

I to am interested in buying a cutter.
Dustin

Still making these also?

Interested...have any in stock?

Called like 100 times, think hes out of it.

Call his cell. I just ordered mine. His cell is (360)649-4465

Ryan

I have both the 30* and the 45* cutters in stock

Thanks
Duffy
D.D.Machine
(360)649-4465

thanks for the orders.
Duffy
D.D.Machine
(360)649-4465

just got a new run of 45* and 30* cutters made ..
Thanks
Duffy
D.D.Machine
(360)649-4465

thanks for the orders