Two ideas come to mind.

Stainless steel roll pin in a cross hole.

A cross hole filled with that plastic that GM puts on the U joints
instead of E clips. Lasts forever, takes a lot of torch to blow
them out on purpose.

(top posted for your convenience)
^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
Keep the whole world singing . . . .
DanG (remove the sevens)




"Koz" wrote in message
...
Hi folks. I was hoping that someone here might have an idea
that would send a project a different direction; Basically
inspiration to get off the path that things are stuck in. I
believe I've asked this before but am re-addressing the issue as
nothing has been resolved yet.

Here's the situation: We need to take a long 1/2" dia CRS rod,
drill the ends 1-1/2" deep x 5/16 and insert a 3" long hardened
and ground dowel pin in the end. The pin doesn't get much
tension but gets some torque in the form of tens of thousands of
cycles over it's life.

Quantity is about 1000 ends a month so it's not enough to get
really fancy or a high investement (IE induction hardening a
journal on hardenable rod instead of using the insert). Cheap
and servicable is the order of the day.

We've tried using a hydraulic compression fit (heavy press in)
which held ok but didn't like the repetative stress cycling for
long enough. We've also tried perimeter welding the joint which
draws out some of the hardness (bad) and takes a little too much
time. Currently, the procedure is to cross drill the 1/2" rod
with a small hole about an inch from the end and plug weld into
the hole and to the pin. This works OK but there is a very
small (5% or so) failure rate over time.

Any thoughts on a better procedure to use off the shelf dowel
pins (or whatever) and get the cycle strength we need? Other
ideas? I'm just trying to "break out of the box" here in my
thinking. Labor needs to be in the range of a couple of bucks
per end.

Thanks

Koz