Machining a keyway is usually a secondary milling operation that adds time to production.
A new device developed by Command Tooling Systems, Ramsey, Minn. (www.commandtool.com), the New Axis Keyway Cutter, harnesses the machining center's coolant system for power, letting it cut keyways and splines without spindle rotation in bores down to 0.5-in. in diameter. It is available in five shank sizes: BT 40, CT 40, CT 50, HSK63A, and straight shank. Four head sizes are each matched with one of three cutter diameters. Odd-sized keyways can be created using multiple passes. The coolant drives a positive-displacement ball-piston motor and provides all the power, with light-duty application needing coolant pressures of 300 psi and heavy-duty jobs needing 1,000 psi or more. The new cutter also loads easily from automatic tool changers.