While I've only seen broken axles in pictures, They usually break at the splines or the middle right?? and with that in mind...

We all know that a six point socket is stronger for removing a bolt than a 12 point, ie when it comes to stripping the head.
and because of torsional force an axle will break in the middle before the ends, if the splines don't give first.
so......
Why couldn't axles be made with a square end vs. splines. Of course someone would have to make a diff that accept these axles, but I think most of us change our diffs anyhow. Aren't splines actually good places for tears to start??

and wouldn't you want an axle that was larger in the middle? Start with a larger bar and mill it down to the square ends?

I know it sounds extreme, but why go through all the extra effort of switching to a stronger, rarer, more expensive axle, when you could just change stuff that would've broken anyhow?

ummm, No.

you dont want an axle thats stronger in the middle. the axles are smaller so they can twist in the middle so they wont just snap. this twist gives somewhere for the force to go.

Originally posted by mossberg
you dont want an axle thats stronger in the middle. the axles are smaller so they can twist in the middle so they wont just snap. this twist gives somewhere for the force to go. umm yeap :D

Good to think out of the box, but unfortunately you have it completely backwards.

A square end would really be like a 4 spline axle.

The socket analogy is not appropriate because you were talking about a 6 point socket on a six point bolt vs. a 12 point socket on a 6 pt bolt. To be valid you have to compare to a 12 pt socket on a 12 pt bolt. Then - the 12 point will be "stronger", assuming other variables equal (like dimensional differences between male and female parts so you can get the socket on (or shaft in) as it were) :flipoff2:

ok i understand your point, but I would still be curious:D But then I think auto engineers would've already done it by now. Making a square end would save a lot of machining on the factories part, i.e. $$. And we all know how they're always trying to save a buck.

Yep and aslo on the axles your shaft diameter by the splines should be the same as the bottom up the spline cut. If they aren't necked down properly the the splines will create stress cracks in the metal. The extra metal doesn't add any strength either.

stripping the splines is not a common problem, snapping right where the splines end is. your 4 spline setup would leave an even more abrupt transfer of size/shape and I beleive cause alot more stress to build up.