Shaft Machining
Brightening Your Ideas with Prototypes
We look forward to working hand-in-hand with you. As a shaft prototype expert, our confidence comes from our hard work and strength.
We focus on providing complete shaft prototypes, expanding our knowledge and experience in this field to provide professional prototype services to many well-known shaft OEMs and suppliers worldwide.
Shaft Machining - KeSuRapid
From proof of concept design reviews and custom parts system development engineering tests to industry projects, from rapid prototypes to custom prototypes, we support all levels of shaft product development processes.
Machined Metal Parts
We specialize in a variety of shaft prototyping developments and rapid manufacturing technologies, providing CNC machining, 3D printing, vacuum casting, rapid aluminum and alloy machining tooling, low volume CNC processes, and sheet metal processing.
The High Precision Machining - Shaft rapid prototyping
01. Comprehensive CNC Machining
The best combination of 3-axis, 4-axis, and 5-axis CNC milling machines, equipped with machine tools with a stroke of more than 1 meter, gives us the expertise to machine custom shaft parts flawlessly.
02. Prototype Achieves High Precision
KeSuRapid company provides a variety of optional cost-effective precision solutions. Rapid machining achieves integrated processes in two or more materials.
- CNC manufacturing team of professional engineers and machinists, optimized NC programming and efficient toolpaths.
- 5-axis continuous CNC machining for greater machining accuracy and flexibility.
- We pay attention to every design detail; Screw spindle or shaft profiles and surfaces are machined to a minimum radius of R0.10mm.
- Excellent surface quality with a finished surface finish of Ra (μm) 0.2 and surface tolerance of ±0.025mm.
- Auxiliary EDM machining is necessary to meet the overall machining requirements of the shaft part.
Types Of Shaft
| Shaft Type | Description | Applications | CNC Machining Considerations |
|---|---|---|---|
| Straight Shaft | Uniform diameter along the length. | Simple machinery, basic conveyance | 3-axis machining, precision turning |
| Stepped Shaft | Varying diameters along the length. | Gearboxes, engines | 4-axis or 5-axis for stepped sections, accuracy in transitions |
| Spline Shaft | Features grooves or ridges for torque transmission. | Power transmission in vehicles, industrial equipment | Specialized tooling for spline creation, precision in fit |
| Flexible Shaft | Designed to transmit power around corners. | Medical devices, remote controls | Complex geometry, requires flexible material compatibility |
| Hollow Shaft | Shaft with a central bore. | Reducing weight in aerospace, automotive applications | Precision boring, maintaining wall thickness |
| Keyed Shaft | Includes a slot or keyway for component locking. | Securing gears, pulleys on shafts | Keyway milling, ensuring alignment |
| Eccentric Shaft | One part of the shaft is offset from the center. | Pumps, vibratory mechanisms | Balancing, precise eccentric machining |
From Small Batch Customization to Pre-Production
We have the ability to provide rapid tooling of both alloy and soft steel and low volume production to deliver your end-use molded shaft parts within 2-5 weeks. We provide cost-effective and rationalized advice from designs, materials, production processes, manufacturability, etc.
Precision Of Shaft Machining
Applications of Shaft Production
- Machinery Manufacturing: Essential for creating shafts for various mechanical systems, defining motion and force transmission characteristics.
- Automotive Industry: Used in transmission systems, axles, and drive shafts for vehicles.
- Aerospace Components: For shaft parts used in turbine engines, landing gear mechanisms, and other precision systems.
- Robotics: For high-precision shaft sets in robotic arms, joints, and drive systems.
- Industrial Automation: In creating shafts for conveyor systems, precision positioning.
Challenges in Shaft Machining
- Complex Geometry: Shafts can have complex shapes including tapers, splines, or keyways, requiring advanced machining techniques.
- Material Selection: Shafts often require materials with high strength and wear resistance, challenging to machine and needing specialized tooling.
- Shaft Straightness and Roundness: Ensuring shafts meet exact dimensional requirements for fit and function.
- Surface Finish: Achieving a smooth surface to reduce friction and wear, especially in rotating parts.
Innovations and Techniques
- 5-Axis CNC Machining: Enables the machining of complex shaft geometries with high precision and efficiency.
- High-Speed Machining (HSM): Utilizes high spindle speeds and feed rates to reduce machining time and improve surface finish.
- Advanced Tooling: Specialized cutting tools and coatings are used to machine hard materials and achieve tight tolerances.
- Turning and Grinding: Specialized techniques for producing smooth, precise shafts or screw spindle.
Comparison of Shaft Machining Techniques
| Technique | Best For | Advantages | Challenges |
|---|---|---|---|
| CNC Milling (3-5 Axis) | Complex geometries, high precision | High accuracy, versatility | Tool wear, material removal rate |
| EDM | Intricate details, hard materials | No mechanical stress, fine detail | Slow process, cost |
| Turning | Circular cross-sections, long shafts | High precision, good surface finish | Limitations in complex geometries, setup time |
Frequently Asked Questions (FAQ)
- What is the typical lead time for a shaft prototype?
- Lead times can vary based on the shaft's complexity and material; typically, we can deliver prototypes within 2-5 weeks.
- What materials can you machine shafts from?
- We machine shafts from a variety of materials, including aluminum, steel, copper, titanium, stainless steel, nickel alloy, and various alloys, depending on the application.
- How do you ensure shaft balance?
- We utilize precision balancing equipment and procedures to ensure that screw spindle or shafts meet strict balance requirements, minimizing vibration and maximizing efficiency.
- What tolerances can you achieve on shaft machining?
- We can achieve tight tolerances within ±0.01mm on shaft manufacturing, depending on the specific features and requirements.
- Do you offer shaft design services?
- Yes, we can collaborate with you on shaft design optimization to ensure manufacturability and performance.