In the realm of gear manufacturing, splines are often overlooked. However, they are among the most commonly used components in rotary machining processes. Splines are widely applied in heavy machinery such as construction vehicles, mining equipment, agricultural machines, and more. Despite their critical role, they have not received the attention they deserve, which is a significant oversight. In practice, splines are omnipresent, serving as essential connections for transferring rotational motion between shafts. When it comes to high-load applications—such as in heavy machinery—complex spline designs (including multi-toothed splines with varying groove types) are necessary to maximize contact area and evenly distribute the load, from the outer to the inner parts of the spline.
Original Equipment Manufacturers (OEMs) and their Tier 1 suppliers demand high-precision components from manufacturers. This is not a new requirement, and many component suppliers have already developed proven technologies for producing splines suitable for use in heavy-duty vehicles. To meet the demands of mass production and improve efficiency, a wide range of conventional high-speed steel (HSS) tools—such as spline rolling cutters, hobs, broaches, and shavers—have been developed. However, the industry is increasingly seeking greater flexibility in spline design. The rapid evolution of spline technology has led to faster development cycles, but historically, manufacturers have struggled with small-part production and design improvements.
Traditional methods involve custom-designed HSS hobs, broaches, or cutters for each set of splines. While these methods work well for long-term, single-volume production, they come with several disadvantages. Excessive tool configuration, complicated specifications, and routine maintenance such as re-grinding and re-coating are time-consuming and costly. These tasks often require removing the tools from the machine and sending them out for processing. Factories typically need at least two sets of the same HSS tools on hand to manage re-grinding and re-coating schedules and prevent downtime.
As technological advancements accelerate in the heavy industry sector, maintaining flexibility to accommodate various specifications, design changes, or small-batch sample production becomes crucial. This requires a comprehensive inventory of hobs for all possible applications. Over time, professional manufacturers have divided their spline and gear product lines into specialized categories, resulting in an extensive list of product names.
Smaller batch production benefits significantly from increased flexibility. Modern multi-axis multitasking machines now allow the use of disc milling cutters to perform operations that were previously only achievable with hobs, broaches, or spline rolling tools. Slot milling or disc milling is the most cost-effective way to produce splines. With the development of multitasking machine tools and blade solutions, a single tool can handle multiple tasks, making it especially valuable for small to medium volume production where frequent tool changes are common.
Sandvik Coromant’s CoroMill 172 disc milling cutter is designed to be versatile across different machine types, aligning with the capabilities of multitasking machines. However, for specific spline sizes and tooth counts, a dedicated insert is required. Customers emphasize the flexibility of the hob due to the adaptability of multitasking machines, such as lathes with driven tools and Y-axes, or machining centers equipped with rotary tables.
For example, a multi-tasking machine can complete all operations on a part without requiring separate setups on a lathe or hobbing machine. This reduces loading time and improves dimensional accuracy. Using a machining center with a rotary table also eliminates the need for specialized equipment, allowing the machine to process other parts alongside splined components. Additional operations like milling, drilling, and planing can also be performed on the same machine.
This level of flexibility enables many manufacturers and secondary suppliers to perform internal spline processing instead of outsourcing to specialized gear shops. With a basic three-axis machining center, a spindle, and a rotary table, even small-scale production can be achieved using relatively simple indexable disc milling cutters. One major advantage of these tools is the ability to replace inserts for different cutting depths, root clearance, or top chamfers, offering greater convenience than traditional hobs or broaches.
Disc milling cutters are also more economical, as they reduce the number of tools needed and allow for the machining of various spline types. This versatility makes them a preferred choice in modern manufacturing. Another benefit is reduced setup time. For axle manufacturers, where each shaft has a small spline, frequent machine changes can lead to wasted clamping time and increased chances of human error. With a multitasking machine and disc milling cutter, these splined shafts can be machined in a single setup, improving efficiency and reducing errors.
Today’s manufacturing plants are seeking simpler, smarter, and more flexible solutions for part processing. The path of least resistance often leads to the best outcomes, minimizing tool inventory and reducing maintenance costs.
When using a disc milling cutter, accurately calculating thin chips is essential for effective spline cutting. Disc mill manufacturers typically recommend two key feed parameters: feed per tooth (fz) and maximum chip thickness (hex). When the radial depth of cut is equal to or greater than the tool radius, these values should match. However, the optimal thin chip effect occurs when the radial width is less than the tool radius.
For a spline manufacturer using a disc milling cutter, the radial cutting width is usually smaller than the tool diameter, ensuring consistent thin chips. To achieve the best hex value and optimize the milling process, operators must calculate fz based on the disc milling cutter’s diameter. The formula for calculating thin chips is illustrated in Figure 1.
If operators cannot optimize the feed per tooth, the feed rate may be too low for the insert geometry, leading to inefficient cutting. Additionally, runout errors in the tool body can cause issues if the hex value is too small, resulting in excessive friction, heat generation, and reduced tool life. Disc milling cutter manufacturers should provide the maximum hex value for optimal performance.
Thin chips play a crucial role in similar milling processes, especially during double-pass roughing, where efficiency is more at risk. By focusing on these parameters, manufacturers can enhance both productivity and quality in spline machining.
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