Custom Shaft Manufacturing: Types & Materials

A shaft is a very useful component that helps with power transmission in multiple applications. Manufacturing shafts is a process that has different techniques.

Custom shaft manufacturing is one of the most considerable requirements in the machining industry, and if you want to learn about it, read the guide below.

What is Custom Shaft Manufacturing?

A shaft is a round and cylindrical component that is used to transfer power between different machine components. The shaft manufacturing process uses different materials and processes based on the application requirements.

The custom shaft manufacturing process is where the shafts are manufactured based on specific requirements. The specified dimensions, material type, and the layout of the shaft are customized.

How to Process Custom Machined Shafts?

The process of manufacturing custom-machined shafts has different steps, and each step plays a vital role. These steps are as follows:

• The first stage is creating the design of the custom shaft in the software. This consists of creating the dimensions, material, and other specifications in the CAD software.
• The CAD software then converts the file into the G-code, which is understandable by the machines. The CNC machine is then set up using the right tool based on the shaft type.
• CNC machining is the most suitable process for manufacturing custom-machined shafts because it offers high precision and control during the process.
• Once the process of manufacturing shaft is completed, it is subjected to post-processing to add finishing to the surface and make it more durable and functional.

Types of Machined Shafts and Their Uses

There are different types of machined shafts, and each type has its own use and performance parameters. Some of the types of machined shafts are as follows:

Hollow Shafts

Hollow shafts are the ones that have a hole in the center so that the wire, fluid, or any other component can easily pass. These are lightweight shafts and are used in aircraft and racing vehicles due to their lower weight.

Threaded Shafts

Threaded shafts are the ones consisting of threads internally or externally. These threads help to create a connection in many applications for attachment and detachment purposes.

These are widely used in plumbing and electrical applications, which consist of lead screws, threaded spindles, and other mechanisms for fastening.

Keyed Shafts

The keyed shaft has a keyway cut, which helps to secure parts like gears, sprockets, and pulleys. These shafts help protect the other components from slipping and create connections for applications that have high torque, such as pumps and motors.

Splined Shafts

The splined shafts have splines or longitudinal grooves that are cut through their length so that they can fit in identical splines.

It helps to create a very strong connection and offers a very seamless transmission of power. They can be used in gear couplings and automobile transmission.

Tapered Shafts

Tapered shafts are the ones that have a reduction in their diameter gradually followed in the length. These shafts are used in applications that require the parts to be very securely mounted, like in pulleys, wheel hubs, and gears.

Stepped Shaft

Stepped shafts are used in drive trains mostly because they can hold cams and large gears for power transmission. They have bearings in the ends, and they are capable of handling axial thrust, bending loads, and torsional loads.

Methods Used in Manufacturing Precision Shafts

The process of manufacturing precision shafts has different techniques, and these are as follows:

CNC-Fräsen

CNC milling is a method in which the rotating cutters cut the blank and create features like keyways, flats, and splines. They can cut the shafts that are in a uniform position in the required shape as they have multi-point tools for rotation.

CNC-Drehen

CNC turning manufactures cylindrical components and precision shafts in cylindrical shape can also be cut through it easily. It offers to produce the shafts with the required diameters and is suitable for high-volume production.

CNC-Schleifen

CNC grinding is a process of machining that uses an abrasive wheel that spins and smoothens the surface of the shaft. It ensures that the tolerance and dimensions required for the shafts are attained.

CNC-Bohren

CNC drilling is a process of drilling holes and channels through the shafts. These holes can lead alloy components to be fixed in the shaft. It can create grooves in the shaft of different depths and diameters.

EDM-Bearbeitung

EDM is a matching method for precision shafts; it vaporizes the workpiece using electricity and cuts small features. It is an efficient method for creating fine details in machined shafts.

Suitable Materials for Manufacturing Custom Shafts

The materials used for manufacturing shafts are versatile, and some of these are:

Aluminium

Aluminium is a type of material which is corrosion-resistant and lightweight. It is highly machinable and suitable for different applications where weight is a concern.

Rostfreier Stahl

Stainless steel is highly suitable for making precision shafts; the major reason for opting for stainless steel for shafts is its corrosion resistance. Hence, marine applications and chemical processing plants use stainless steel shafts.

Titan

Titan is selected for shafts due to the excellent corrosion resistance and good strength-to-weight ratio offered. It is used for aerospace applications.

Kohlenstoffstahl

Carbon steel has high machinability and tensile strength. Hence, it can withstand heat and is used in motors and pumps due to its properties.

Legierter Stahl

Alloy steel 4340 and 4140 are mostly opted for precision shafts, which are used in heavy-duty industries. Alloy steel offers toughness and high strength, making it suitable for industrial applications.

Nickel-Legierungen

Nickel alloys are suitable for manufacturing shafts that are required in applications related to turbines and where high temperature prevails. It is known for its strength against high temperatures and corrosion resistance.

Surface Finishing Options for Custom Machined Shafts

Custom machined shafts have different surface finishing options and some of these are given below.

Eloxieren

Eloxieren is a surface finishing choice that is ideally opted for aluminum-based shafts. It creates a layer on the shaft, which ensures corrosion resistance and even enhances the look due to the different colors and textures offered.

Passivating

Custom shafts are also improved in terms of the surface using passivation. It's mostly chosen for shafts made using stainless steel.

The process of passivation cleanses the surface of the shaft with an acidic solution. It removes the free iron components from it and creates an oxide layer.

Perlstrahlen

Bead blasting is a process in which either fine glass particles or steel beads are projected toward the shafts using high pressure. It removes the impurities from the surface and adds a clean finish.

Galvanik

Galvanik is a surface treatment that improves the surface of the shafts by depositing a layer of nickel, gold, or zinc on the shaft. It enhances the resistance of the shaft against corrosion and wear.

Polieren

Polieren is a method of surface finishing that keeps the shafts away from oxidation. It also helps remove scratches and marks from the machined shaft.

Chrome Plating

Chrome plating is a thin layer of chromium deposited on the machine shaft. It helps to improve the sealing of the shaft and adds hardness.

Tips for Manufacturing Custom Shafts

The tips below can improve the process of custom shaft manufacturing and provide you with high-quality machined shafts.

• Consider the torque and load that the shaft will have to handle and accordingly determine the reliable material and diameter.
• Analyze the strength and durability of the material when choosing it for a machined shaft in the light of the environment in which it will be used.
• The application requirement determines the length and diameter of the shaft and also chooses a cross-sectional shape that can handle the load.
• The surface finishing option should be chosen with the intent of the durability of the shaft and its resistance against corrosion.

DEK’s Shaft Manufacturing Capabilities

As an experienced manufacturing company in the machining industry, we at DEK know the significance of accurately and precisely manufacturing custom shafts.

We use various CNC machining methods and manufacture a custom shaft for your applications, ensuring its excellent surface finish.

Schlussfolgerung

Custom shafts are manufactured keeping in mind the need for application. The process of custom shaft manufacturing will take into account dimensions, materials, and the type of shaft needed.

So, as you have gone through the guide above, you must have understood everything about manufacturing custom shafts in detail.

FAQs

What is the standard tolerance for precision machined shafts?

The standard tolerance of the machined shafts ranges from +/- 0.01mm to +/- 0.05m in terms of diameters and +/- 0.1 mm to +/- 0.2 mm.

What is the purpose of a machined shaft?

Machined shafts are used for power transmission between components in the engines and machinery.

What machining technique is ideal for manufacturing a shaft?

CNC turning is the ideal processing method for manufacturing shafts.