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Old 07-07-2020, 06:47 PM   #7
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Join Date: May 2010
Location: Windy City
Posts: 2,882
Default Re: O/T What material would you use for new axle shafts?

1144 'stressproof" and do not heat treat it. You need to watch what you buy with 1144, as some of it is approx RC30, some as low as RC15. I would avoid anything supplied under RC20. Keep the feed speed down and flood it with water-soluble while cutting.

McMaster Carr carries several grades of 1144 and you can order just one foot of one inch stock for about $12 if you want to try it with your splining cutters and setup for machine-ability/ finish and fit.

I made plenty of replacement foundry shakeout machinery shafts from the stuff in the '90's and they never snapped like the original shafts they replaced.
Mechanical engineering 101: If you put an adjustment knob, screw, bolt, or tolerance specs on something, some people will immediately fiddle with it. If you mark it DO NOT TOUCH everyone will mess with it.
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