Making Keyways

Grinding Exterior Keyway

Use cutoff grindger wheel and guide, then use a dremel to clean up:

Brute force with grinder:

Summary of grinder route:

1. Use cutoff grinder wheel with guide to make the sides. Use a guide clamped on the shaft. This provides the straight, vertical edge
2. Use a larger grinder wheel to bore out between the sides.

Internal with Grinder

For 2" or larger: doesn't really exist.

Use a reciprocating broach, or parting tool blade if you don't have a broach

Universal Axis

• Simply mount a needle file on a Universal Axis - based reciprocator, and let it CNC all night long to make a perfect keyway very slowly. With 10 micron step size, this should not be a problem. Working out functional parameters would be a good project for a student. Needle files: [1]
• The above is inspired by this: