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Making a Woodruff key

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Danny M2Z	08/11/2013 13:34:49
963 forum posts 2 photos	G'day. I have been asked to make a Woodruff key for an electric motor driving an aluminium gear (mates rates, payment in stubbies). So what is the best way to approach such a simple job? I thought of using plasticene to get the diameter, turning and parting off a disc and then milling it to fit. Might paint it dayglo to help find this one. Any pointers? Regards from the land of the kangaroo * Danny M *
Tony Pratt 1	08/11/2013 13:59:29
2319 forum posts 13 photos	Turn to the reqd diameter, mill the flat & then part off to get the key, well that in theory should be the best way Tony
Gordon W	08/11/2013 14:08:06
2011 forum posts	I've made a couple of keys in the past. Just saw of a slice from a high-tensile bolt of the right diameter ,file to thickness and cut of to correct hight. Keys are made to standards, see mHand book.
JasonB	08/11/2013 15:52:05
25215 forum posts 3105 photos 1 articles	Plent on e-bay and they are not expemsive and likely to be a better fit and the correct hardness. J
jonathan heppel	08/11/2013 17:30:42
99 forum posts	A woodruff in an aluminium pulley might as well be mild steel- no point in using anything fancier. They shouldn't really be used for transmitting much torque anyway. The keyways are usually cut quite closely to nominal size. so I've parted off a disc a thou or so over, fitted with a file etc, then milled or more often sawn and filed to fit the pulley, If a close fit isn't necessary, eg if you're loctiting it, just aim for nominal size and it'll be fine,

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