AN APPROACH TO DEVELOPMENT OF INVOLUTE SPLINE ON

LARGE PARTS USING CNC MACHINING

A.Velayudham1*, Prasmit Kumar Nayak2, A.M.Junaid Basha3

1
*CVRDE, Avadi, Chennai, 600054, vel_sivam@yahoo.com
2
CVRDE, Avadi, Chennai, 600054, prasmit1@gmail.com
3
CVRDE, Avadi, Chennai, 600054, junaidbashaam@yahoo.com

Abstract
This paper describes the approach followed in machining involute spline on a crank shaped large size component using CNC
machining centre. For spline milling shell type tool holder with throw away involute formed coated carbide inserts were used.
To verify the involute geometry of the splines machined by CNC milling, on the similar size component involute spline form
was generated on gear shaping machine with the same spline data. Comparative results of profile, lead and pitch errors are
presented for involute splines obtained by spline milling and spline shaping processes. The accuracy of results is better for
spline milling as compared to spline shaping.
Keywords: Involute spline, CNC machining centre, Throw away carbide insert, Spline shaping.

1 Introduction crank pin is therefore, plays a vital role in sustaining the

In a metal cutting production environment, with mixed
production and limited time for optimal planning particularly
for small batch runs is always a critical one. While optimised
solutions are always the desired choice, in these environments
the need is for a versatile, flexible and reliable solution, with
reduction in setup time often demands a different solution
[R.W. Jones, 2007]. Gear / Spline manufacturing is a
relatively complex area, spanning over a broad spectrum of
components, where volume, complexity, size, quality and
costs are the main factors that determine the production
methods and machinery. Moreover, it is an area where
conventional methods have been applied to meet the demands
that these factors make [Christer Richt, 2012]. Designing
techniques to manufacture involute spline and gears on large
sized components is always a challenging one. In this paper a
conventional method of involute spline form milling using
CNC milling machine on large part is discussed. The involute
spline machining was also carried out on the similar
component by spline shaping machine. The results of profile,
lead and pitch errors are compared.
2 Description of component
Axle arm is one of the critical members in hydro-
pneumatic suspension system (Figure 1) of combat vehicle.
Its main role is to transmit the undulations encountered by the
rim wheel to the suspension system to dampen the vibrations
experienced by the vehicle while moving on different terrains.
Basically axle arm consists of two important portions, viz.
stub axle and crank pin besides its basic arm. The main
function of the stub axle is to support rim wheel assembly and
the crank pin is to connect the crank that is housed inside
suspension housing. On the stub axle, rim wheel is supported
by two bearings and the crank pin is supported by another two
bearings assembled in the housing. The undulations of the
terrain experienced by the rim wheel are transmitted via axle
arm, crank, connecting rod and the dampening valves. The
dimensional and geometrical accuracy of involute splined
transmitting load and torque during movement of the combat
Suspension housing
Crank pin
Rim wheel
Axle arm
Stub axle
Figure 1 Hydro-pneumatic assembly
vehicle. In addition to transmission of torque, spline profiles
are used to centralize the axis between a splined shaft and a
splined hub located in the mating part [Norbert Weiss et al,
2004]. In a large sized component, controlling the geometrical
tolerance is critical, since any small variation in the axis will
get amplified when the centre distance is more.
The detail of the axle arm is illustrated in Figure 2. In the axle
arm, the axes of the crank and stub axle are apart to a
distanceof 550±0.5 mm and should be parallel within 100 µm.
The bearing diameters Ø100g6, Ø140h6 and the diameter of
involute spline are to be concentric within 20 µm and their
axes must be perpendicular with the basic arm within 20 µm.
While it is possible to achieve this with major diameter/minor
diameter fits of the mating splines, the true centring effect can
only be achieved by using involute splines.The involute, or
"side fit" profile is the most commonly used spline in
production today. Therefore to assure the assembly between
suspension housing and rim wheel, side fit involute splines
are specified in the design of the axle arm.

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 rolling are some of the common methods followed in
Ø139.5h11
industries to produce involute splines and each having its
inherent merits and demerits and applications [Dan Seger,
Ø100g6
2005]. Splines are generally produced in dedicated gear
Spline production machines, which use tools in the form of hobs and
202.5
186 R35 550±0.5 disc cutters. With the goal of producing a given batch of
Ø140h6 components to the required dimensional accuracy with
140 91 minimum cost and in the least amount of time, advancements
Crank Pin in technology need to be continually investigated to find tools
Arm that can have a direct impact on customer’s quality, cost, and
350.5 delivery. For components having many features, including at
Stub Axle least one gear element, there is an increasing trend towards 5-
axis machines capable of multi-tasking. The ability to
150 completely machine components in one or two setups, for
quality and cost reasons, is a strong driver of change. Apart
Figure2 Axle arm from quality, the size of the component also drives the
production method.
The raw material of axle arm is steel forging to BS: 970- In this study, the component is crank shape, and the size of
1991, Part 1, 832M13 (En 36C). The detail of the composition the component is quite large with a swing of 700 mm from
of the raw material is given in Table1. Stub axle side of the the centre axis of the crank pin. To machine involute spline
axle arm is case hardened to a depth of 1.2 to 1.5mm with 50 on this crank shaped large part at gear hobbing machine is not
to 55 Rc and finish ground. The remaining portion shall be possible. Although gear shaping process is quite appropriate
hardened and tempered to a minimum hardness of 340BHN. to process external spline on such a large and crank shaped
The splinedata is as per DIN standard [DIN 5480-1, 2006] component, gear shaping machine with higher capacity rotary
which is given in Table 2. table of 1400 mm diameter and higher stroke length is not
quite commonly available in gear manufacturing industries.
Table1Chemical composition Above all, achieving the exit radius of R35 mm at the spline
Composition (%) end is difficult with gear shaping process. This situation calls
Elements for an alternate method of manufacture. Hence, to meet these
Min. Max.
C 0.16 0.18 criticalities a conventional approach of form milling with
Si 0.26 0.35 involute shaped form cutter was adopted. To meet the large
Mn 0.50 0.60 swing and indexing requirement of the component, a
Ni 3.50 3.75 precision CNC machining centre with large CNC rotary table
Cr 0.93 1.10 was selected. To ensure the exit radius that is required at the
Mo 0.20 0.25 exit end of spline, a suitable size form milling tool holder was
Cu - 0.35 chosen.
S - 0.03 Gear milling is characterized by interrupted cutting action,
P - 0.03 and in addition to thermal variations on the cutting edge,
Table2 Spline data mechanical interruptions make demands on high insert
toughness and strength. In gear milling the demands for edge
Reference diameter ‘d1’ 140 mm toughness are also influenced by the relatively small radial
Module ‘m’ 2.5 mm depths of cut in combination with the large tool diameter
No. of splines ‘Z’ 54 [Steven Van Dyck, 2011]. To meet the productivity needs
Reference profile DIN 5480 with huge batch sizes, traditional high speed steel tools, such
Profile modification X1.m +1.125 mm as spline rolling racks, hobs, broaches and shaving cutters,
Total Depth ‘h’ 2.5 mm have done the job admirably. However, there is a push for
Quality zone 8f DIN 5480 increased flexibility. A leap forward on the flexibility
Base tangent length Nominal 72.026 mm continuum is happening now, due to present development in
‘W’ across 10 teeth Aoe 71.982 mm multi-axis and multitasking machines to perform operations
Au 71.947 mm given exclusively to hobs, broaches, spline rolling racks and
other tools in the past. With multitasking machines and new
3 Manufacturing approach insert developments, it is possible to have a single cutting tool
accomplish several operations. This is especially crucial for
Over the decades, numerous methods and manufacturing small to mediumbatch production, which often requires
processes have been used in making the various kinds of frequent changes throughout the machining and handling
splines based on various criteria, including applications, process [Aaron Habeck, 2014]. When compared to traditional
reliability, life time, processing time and manufacturing cost. high speed steel tools for gear milling, the new generation
Milling, hobbing, grinding, shaping, broaching, slotting and

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coated carbide inserts offer a completely new scope for commonly used solutions. CMMs can effectively measure
reducing machining times, cost and improving the product both splines and other production parts, which is their primary
quality [Christer Richt, 2010]. In this study, considering the advantage over conventional gear measuring devices [Belinda
material composition and heat treatment condition of the Jones, 2011]. In this study, the spline form milled component
component, suitable grade carbide insert was chosen. (marked as ‘Part_S_1’) and spline shaped component (marked
Stub Axle portion of the raw Axle arm forging was initially as ‘Part_S_2’) are inspected on Carl Zeiss three coordinate
turned in Vertical Turret Lathe / CNC vertical CNC milling measuring machine. The data was measured using Gear Pro
machine (by circular interpolation followed by external gear measuring software and compared with the standard data
turning using Wohlhaupter facing and boring head). The given in the DIN 5480, part 1. The results with respect to
Crank Pin portion was then machined as adopted at Stub axle profile, lead and pitch are illustrated in Figure 4 and Figure
side by holding on a milling fixture. To carry out the spline 5.The inspection report of the above results of profile, lead
cutting, vertical CNC Machining centre which is having a and pitch errors are summarized in Tables 3, 4 and 5.
CNC rotary table was used. Here a right angle head was
utilised for carrying out spline cutting horizontally.Initially, to Table 3 Profile error between Parts S_1 and S_2
prove the process an end mill type involute form cutter that is
made out of solid carbide was tried. The machining trials Profile Error (in µm)
Sl. Tooth
were conducted on a SIP 5000 Jig boring class double column Allowable S_1 S_2
No No.
vertical machining centre. After proving the process, a seven- limit LH RH LH RH
flute shell mill holder with three cornered throw away TiCN 1 1 21 13 5 10 21
coated carbide inserts, tailored to the involute geometry as per 2 15 (As per 14 12 20 17
DIN standard (Vardex make) was used to carry out spline 3 28 accuracy 13 10 12 36
milling operation. The set-up of spline milling is illustrated in 4 42 grade 8) 11 7 14 17
Figure.3. To compare the accuracy of form gear milling, a
shaft to the size of crank was machined and spline was Table 4 Lead error between Parts S_1 and S_2
generated using shank type spline cutter utilising Mitsubishi
gear shaping machine.The results are compared and discussed Profile Error (in µm)
Sl. Tooth
in the following paragraphs. Allowable S_1 S_2
No No.
limit LH RH LH RH
1 1 11 10 10 15 14
2 15 (As per 13 11 27 33
Shell mill holder 3 28 accuracy 12 11 21 15
4 42 grade 8) 11 9 27 26

Axle arm
Table 5 Pitch error between Parts S_1 and S_2
Pitch Error (in µm)
Sl. Tooth
Allowable S_1 S_2
No No.
limit LH RH LH RH
CNC Rotary 1 1 17
table 2 15 (As per
19 21 23 42
3 28 accuracy
4 42 grade 8)
Figure 3 Spline milling set-up
It can be seen that the profile deviation observed when
4 Results and Discussions machining by the process of CNC milling is nearer to the
tolerance grade of 7, which is well within the required
All types of gears / splines require dimensional verification tolerance grade of 8. But the profile deviation observed from
to ensure reliable, long-term performance. The spline on shaping process is closer to the tolerance grade of 10, which
workpieces can be inspected in different ways viz. inspection clearly shows that the approach followed by CNC form
of the individual form on the measuring machine (profile, milling meets the design requirement and thus suitable for
helix trace, pitch, and run out), double flank gear rolling machining involute spline on large part. In the case of CNC
inspection on a double flank gear rolling inspection machine, form milling, the involute profile is formed by direct
where proper master spline is mandatory. A variety of 3D replication of tooth space by the involute profile ground
coordinate metrology technologies are utilized to inspect and carbide inserts, due to which the required profile accuracy is
measure gears / splines from stationary coordinate measuring achieved. However in the case of spline generation through
machines (CMMs) to portable laser tracking systems. Optical gear shaping machine, the inherent inaccuracies in the gear
sensor technologies, as well as tactile measuring devices, are kinematics and the inaccuracies resulted in the gears linkages

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 Figure 4 Inspection report of profile, lead and pitch of
involute spline milled through CNC form milling process

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Figure 5 Inspection report of profile, lead and pitch of
involutespline generated through shaping process

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due to normal usage of machine would have caused this Christer Richt (2012), Sophisticated simplicity, Metal working
variation. Apart from the above, error in setting the blank axis world, pp. 26-27, Feb 2012.
in-line with the axis of machine table also could have resulted Dan Seger (2005), Inside Splines, Gear Solutions, pp. 32-35,
into the above variation. However it is to be noted that the Jan 2005.
variation between the tolerance grade of 8 and 10 is very DIN 5480-1 (2006), Involute splines based on reference
minimum for the module of 2.5mm. diameters – Part 1: General.
Based on the variation with respect to lead, the tolerance Norbert Weiss, Rudolf Och and Jerry Kowalsky (2004), Side
grade observed from CNC milling process is 9, whereas from Fit Spline Profiles, Gear Solutions, pp. 40-43, Mar 2004.
the shaping process it crosses the tolerance grade of 12. Jones, R.W (2007), A New Tool for Prototype and Production
Therefore with respect to lead, the tolerance obtained by the – Case Study, Gear Solutions, pp. 40-43, Mar 2007.
process of CNC milling is much closer to the design Steven Van Dyck (2011), The Case for Cold Rolling, Gear
requirement of 8 tolerance grade. Based on the pitch variation, Solutions, pp. 46-52, May 2011.
it is observed that the tolerance grade achieved by CNC
milling is 9 on both left and right flanks, whereas by spline
shaping process the left flank is grade 9 and right flank is
grade 11. Therefore, based on the pitch, the variation is almost
same in both the cases.
The above results clearly indicate that, approach followed
by form milling using throw away carbide insert utilising
CNC machining centre is quite suitable to machine involute
spline on large parts. The results also suggest that to achieve
closer side fit 8f tolerance grade, alternateprocesses like spline
hobbing or rough machining by shaping followed by grinding
can be resorted.
5 Conclusions
From the study on spline machining through form milling
using CNC machining centre, the following conclusions can
be drawn:

The profile deviation observed when machining by the
process of CNC milling is nearer to the tolerance grade of
7, which is well within the tolerance grade 8 specified in
the standard. But the profile deviation achieved through
shaping process is closer to the grade of 10. With respect
to lead, the observed deviation through CNC milling
process and conventional shaping process is 11 to 13 µm
and 15 to 27 µm respectively.

The measured variation of pitch while machining through
CNC milling is 9 to 19 µm and by shaping process is 9 to
23 µm against the allowed variation of 8 to 17 µm.

From all the results, it can be seen that approach followed
by form milling through throw away carbide insert using
CNC milling machine is quite suitable to machine
involute spline on large parts.

The results also suggests that to achieve the closer side fit
8f tolerance grade, alternate processes like spline hobbing
or roughing through shaping followed by grinding can be
resorted.
References
Aaron Habeck, (2014),Speedingup Splines, Modern Machine
Shop, March, 2014.
Belinda Jones (2011), Putting teeth into gear inspection, Gear
Solutions, pp. 45-54, Aug 2011.
Christer Richt (2010), Anew edge on gear milling, Gear
Solutions, pp. 22-30, Apr 2010.

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