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Lcubed, Is is Tensile or Yield? My guess is it is 1.81 time ultimate tensile strength.

Electricpete, I read some studies awhile back that said that 120 was the ideal for 2 keyway system.

Why not try a second keyway 120 degrees from the first? Obviously one keyway is not working.

I think part of the answer lies in how you want to use this. Do you want the part to shear as in a shear pin or do you want it not to shear.

Sounds like a good question. I would go to the manufacturer for this information. Let us know the reply.

Try this: http://www.thomasnet.com/products/bolts-large-diameter-6611008-1.html

Try this: http://www.mesteel.com/info/equivalent.htm

Just out of curiosity. Have you done a hardness check on the A36 steel? I wonder if it has been work hardened by your heavy loads. How wide are the wheels? 1/4 thick seems like an adequate thickness. Have the cam follower wheels embedded into the soft steel? Are you certain that the cams share...

I am with the tick. The illustrations show a groove that allows for the the spline or thread to be fully cut across that section of the part. The chamfer is probably an option to create less of a stress raiser or to clear a radius on the tool that cuts the groove.

Is grain directional? Can aluminum be coined?

Try this. http://www.thomasnet.com/products/metric-bolts-6640502-1.html?WT.mc_t=pi&WT.mc_n=y&WT.srch=1

Do you mean M16 x 30mm long bolts? Increasing the space between centers will increase the load on the bolts unless as rd1957 points out that you are increasing the pitch line or moment radius of the bolts.

Screwman, If the spline drive is not better, why was it developed? Why has it not been obsoleted?

I happended across an e-mail from my Sister in California that was addressing HHO Weld Technology. Sounds too good to be true. Any one using it? Is it a hoax?

Why did it happen only at low speed?

BP210R 63mm EPDM Russell-Stanley , Sonoco, Greif , most other U.S. made plastic drums 8 lbs. Click here for prices or to order http://www.ba-industrial.com/drumplug.htm

Have you tried looking as 2.5 inch diameter threads?

Have you tried using loctite on the interfaces? Sounds like a creep phenomenon.

We modified the active thrust brg to a tilting pad design. Everything else on the machine stayed the same. Why???

If your torque is fixed at 20Nm, it seems to me that defines the pressure and preload of interfaces.