Precision Keyway Cutting

In addition to our extensive gear cutting capabilities, at Industrial Sprockets & Gears, Inc., we have one of the largest keyway cutting machines in the region. The part shown here is a dye block roller that is 6′ in diameter and 22″ in length. The customer needed a 4″ wide keyway cut down the 22″ length of the roller, and had not been able to find a machine shop capable of taking on the project prior to contacting us. Since that roller is made of heat treated 4340 steel, which has a Rockwell hardness on the order of 42C, specialized tools were required to create the keyway.

Our team has an extensive depth and breadth of experience in the design and fabrication of custom tooling used to produce precision gears and sprockets. That experience also applies to the machining capabilities required to make related components such as precision shafts. We can create new parts, repair existing parts, or reverse engineer replacement components based on a physical sample.

Tolerances for the keyway were held to dimensions as tight as ±0.002″ and verified using the measurement over cord inspection method. We were not only able to complete this job when other shops had turned the customer down; we were able to cut the keyway for this 7,000 lb. roller with a turnaround of two days. As a manufacturer ourselves, we understand the difference turnaround time makes when customers are facing production downtime. For additional information about this custom keyway cutting project, contact us directly.


Product Name

Dye block roller

Product Description

4″ wide x 22″ long key-way

Capabilities Applied/Processes

Primary: specialized tooling

Equipment Used to Manufacture Part

#8C mitts & merrill key seater

Overall Part Dimensions

6′ round. 22″ long

Tightest Tolerances


Material Used

4340 Heat treated

Material Finish

machine finish

In process testing/inspection performed

measurement over cord

Estimated Part Weight

7,000 lbs

Industry for Use

Dye block for rolling dye

Delivery Location

Los angeles, CA