things would have been a lot easier if the key way was done before the shaft was attached to the drum. now that it is welded to the drum you need a really big machine to cut the key way the way you have things now. might be able to cut it on a Bridgeport style mill with the Y axis if you can use a fork truck to hold it up while you cut the key way and maybe a roller under the other end of the shaft once you get things straight and on center so it can move with the table. i would leave the forks there to catch it if something would slip. doing something like that is not the safest way to do things. the safest way would be to pull the shaft out if you can? i'm not sure what machines you have to work with either?
The following user(s) said Thank You: thefabricator03
I was thinking a bit more agricultural than using a mill.
1mm cutting disc on a 5 inch grinder. Drill two holes either end the correct depth cut slot width underside and grind out center with 5 inch grinding disc. Then finish by had with a file.
Not fun but would be easier than taking the shaft out.
I am going to see if any of the local mining workshops around here have a machine to do onsite keyways. My guy who use to do a lot of on site line boring is not here today so I will ask on Monday.
another option would be something like this but they are not cheap if you would have to buy one. but you would probably get your money out of one if you run into this kind of thing often.
The following user(s) said Thank You: thefabricator03
Its not as though the shaft will be spinning at high speed and the load will never be balanced.
Why don't you machine a flange to fit the shaft that has some bolt holes on a PCD and weld it onto the shaft? Then you can just bolt your sprocket on. Worst case, you'd have to be creative working out how to drill the matching holes in the sprocket assuming it hardened steel.
i think that sprocket is set on tapers and when the screws get tight it compresses the sleeve and tightens on the shaft. the key way is extra measures to keep things from spinning on the shaft. high speed is not the issue but driving all the weight of everything needs the key way. the sprocket design might not work well doing something like that. i think we could be stuck with the design as it is and getting the key way in the shaft. you might be able to sleeve the shaft and key the sleeve then stake the sleeve to the shaft but that all depends on the material amounts in the bore of the sprocket.
The following user(s) said Thank You: thefabricator03
