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WKT - the pump will not fit in any other location. Believe me, if we could have put the pump next to the engine and powered it via gearbox bolted to the engine, we would have done so. It would have avoided this shaft and also been more simple overall. But it just wouldn't fit. Also, if we...

Correct, internal combustion with pistons and cylinders. I suspect this is why the Dudley spline analysis is saying I should select a material with 286ksi strength, even though the calculated steady state load is only 20.5ksi.

Thanks again guys. What can I do to make the part easier to manufacture? It has to span a 24" long gap. I can use a larger OD (1"?) if that makes manufacturing easier. But the splined ends will still have the smaller OD (the minor diameter of the tooth radius is 0.707"), and I can't change...

Thanks Ed. It is an involute spline. It's a very outdated Air Force Navy Aeronautical standard, published in 1953 and then canceled in 1993. But it's what we've got to use because it's what the pump uses, and we can't change the pump. 20/30 pitch, 30 degree pressure angle, flat root, side...

Hello! I could use some advice on selecting a material for a splined shaft. This is a newly designed prototype. The shaft is small (0.707" OD, 0.375" ID, and about 24" long). It connects an internal combustion engine (prime mover) to a hydraulic pump. At peak design load of the hydraulic...

Thank you all, this has been a very helpful discussion Jon

Correct. How do you bond two parts that don't have a perfect fit? Also, I don't understand why this discussion is making such a big distinction between a liquid shim and a bond. In many cases, the same adhesive is designed for use as a shim and for use as a bond. In fact, the adhesive we...

Bingo! There must be some way to bond components that don't have a perfect fit up. That's the crux of my question. Thank you all again!

Okay, so how do you adhere two components that don't fit perfectly together? For example, I cannot imagine that Boeing and Airbus are manufacturing wing skin / stringer assemblies that have 0.005" or less gaps across the entire wing surface. There must be gaps. How are they filling the gaps...

SWC and Blakmax - I am listening. 100%! I am just confused. You are worried about the long term durability of the joint due to corrosion. You are also worried about how we are calculating the design loads and whether we should rely solely on adhesive or solely on fasteners or have both...

Wow, so may naysayers! To address some of the specific questions: Yes, we agree. There are additional steps we'll take for corrosion. That's only for aluminum. Our stack is steel and carbon. At first blush, I understand your concern. But the shim is obviously part of the load path...

It's a Hysol epoxy designed for bonding metals and serving as a liquid shim. 5000 psi lap shear at room temp.

All - thank you very much. Quite helpful. To answer some of the questions: 1) The paste adhesive is a Hysol product, which Henkel recommends for use as both a general purpose adhesive and also as a liquid shim 2) The steel surface will be grit blasted shortly before adhesive application...

Hello all. We are working on a design where a carbon composite panel is fastened to a 4130 steel subframe. The subframe has flat mounting flanges for the carbon panel. The carbon will be attached to the mounting flanges using both an epoxy paste adhesive and Hi-Lok pins. Basically, the...

Good question, but no, the bearings should not be over-torqued. The bolts are undersized compared to the spherical bearings. There is a "top hat" bushing that fills up the extra space between the bolt shank and the bearing bore. For example, a 1" bore bearing will use a 5/8" bolt.

Hello everyone! We are having a debate with the mechanical people who actually have to assemble, disassemble and service our designs. They have a strong preference to apply grease or anti-seize to all bolt shanks before assembly, as they think it makes the parts easier to assemble and...

Thanks Wil. Very informative, as always. And I answered your question wrong on Helicoil installation. We are indeed using a pre-winder tool to install the Helicoil. We are using a screw diver to install the screw. I don't think you could get the Helicoil into the hole without the...

NAS603-18P 2TLF-3C-0380 we use a screwdriver... :)

Got it. Thank you all. Very helpful!

3DDave - thank you. We won't consider this a defect. But it does raise some corrosion questions... Hmmm. Need to think about those. Dik - thank you, but not helpful! Cadmium is a standard finish in aerospace. Millions and millions and millions of fasteners are cad plated. We can't just...