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The forum did not accept the greek characters I imported. Please note ?=(.970/2) = .485 should read: rho = (.970/2) = .485 ?max = T?/J should read: Tao max = T * rho / J

Thanks GMI We produce the converters we use. I incorrectly assumed the converters to be fully locked at the end of the sled pull. Our converters have a torque multiplication of 2.5-2.8. This does help explain the failures. I will revise the calculation and assume 25% loss in the...

Thank you TVP. I also want to say, thank you for your patience, to everyone else that participated in this discussion. I am going to pursue a billet machined two-piece design using 300M for the shaft and 4340 for the drum. A stress relief will be added behind the splines. I have a few more...

I over simplified my stress calculation description. The stress I calculated did not consider stress consentrations or loses in the transmission. I merely calculated the max torsional shear stress for a .970 OD X .312 ID tube subjected to 350 ft-lbs of torque (686hp high performance truck)...

More I am asking how to specify that I want to start with a forging and then machine the part to the finished dimensions. The details from forging to finish part is what I am hoping to gain from this part of the discussion. The normalizing before machining is an excellent example. Thank you...

Cracking does not occur btw the diameter change. The lowest gearing usable would be 1st gear 2.54, 4 low 2.72, and rear diff ratio of 3.73. Total reduction: 25.68 The stresses calculate to be 24000psi ~165MPa. This number was determined using the torque measured on a chassis dyno and does not...

Where can I post the pictures? I assumed I could post them in this forum, but I was unable to.

Currently I have a design to increase the .970 portion of the shaft to 1.275. At the same time we will be offering the stock size shaft in a stronger billet / forged construction. If we are already using the best material then I will focus on the design and eliminate as many stress...

Currently we are using a material that I am told is a modified 4340 called 300M. The shafts that fail show helical cracks down the length of the shaft. The failures have all shown up in trucks that are subjected to large amounts of towing. The currently the shafts are machined from 300M billet...

Thank you rootem. Mark Jean was very helpful and led me to a good source.

I am trying to make a tubing assembly for a dual fuel pump system my company sells. The working pressure of the system is 28,000 psi. The factory high pressure fuel lines are 8mm OD and 3mm ID. They are made of a steel alloy. I am trying to find a tubing supplier or someone who will build the...