During the processing of a toothed sleeve in our company's manufacturing workshop, an issue was identified where the internal spline and the central hole were misaligned due to a machining error. This resulted in a portion of the spline being missing, with the affected area reaching up to approximately 2mm in depth. Since all components of the product had already moved into the final assembly stage, and the delivery deadline was fast approaching, it was decided to proceed with repairs while ensuring that the product's performance would not be compromised.
As the toothed sleeve had already been completed, a detailed inspection was conducted using the machine tools available in the processing workshop. Each component was measured, and non-conforming areas were marked with a marker. The thickness of the missing material was also noted. Upon completing the inspection, it was found that apart from the lack of machining on one side of the internal spline groove (as shown in the drawing), all other dimensions were within the acceptable tolerance range. The defective area measured approximately 60mm by 400mm, with the machining loss ranging between 1 to 2mm.
**Weldability Analysis**
The material used for the toothed sleeve is 40CrNiMoA, a high-strength alloy steel commonly used in applications requiring excellent mechanical properties and toughness. Its chemical composition is listed in Table 1 below:
| Element | Content (%) |
|---------|-------------|
| Carbon (C) | 0.35–0.42 |
| Chromium (Cr) | 0.80–1.10 |
| Nickel (Ni) | 1.20–1.60 |
| Molybdenum (Mo) | 0.15–0.25 |
| Manganese (Mn) | 0.30–0.60 |
| Silicon (Si) | 0.15–0.35 |
The internal spline structure is shown in the image below for reference.

*Internal spline structure*
For more detailed information, please refer to the attached document or consult the 18th issue of *Metalworking (Hot Processing)*.
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