Machining on a Carbon Steel Shaft

What is the hardness? Do you have a way to test it?

No, I can't measure it. Is there any way to measure it?...

Just for kicks, take any standard file and see if you can cut the shaft. Note what kind of force produces marks (if any). If you can not mark the shaft with only slight force, you can not machine with standard tooling. Depending on the end use of shaft and required tensile strength needed. A hardened shaft may not be the best choice, but also the cost to install a key can out way the cost of proper materials to do the job.

Use a simple and cheap poldi equipment - must be available everywhere.

If your hardness is higher than 45HRC you are likely to have problem. Upto about 30-35 HRC it is easy.

You are likely to have a shaft that had been - Low carbon steel carburised/nitrided or High carbon steel Quenched and tempered/ Induction hargened.. I don't expect a through hardened shaft - unless - it is a small dia shaft.

One of the best way will be to grind the keyway (if it is small one) - we are sometimes forced to do it in a few bearings where antirotation slot is not provided.

We use tool grinder and grind the slot with flat wheel. But then these are only about 10mm wide and almost same depth.

In case of larger keywat it will be problem.

BTW- on hardened shaft removal of the top layer - is it advisable?

UD15