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Unread 05-07-2014, 18:03
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Re: pic: 2-Speed Gearbox

Quote:
Originally Posted by Infinity2718 View Post
You may need slightly larger fillets in the pockets to allow for a bigger endmill to work around. I would think a .125" radius would be nice for at least a 1/4" endmill, but more experienced machinist could chime in on a nice cutter size. The larger fillets will also reduce stress concentrations, strengthening the plates.
Agreed. A .250 endmill is where you want to be for these sorts of plates. It's actually significantly stronger than a 3/16th endmill. Even if you're waterjetting the plate, I'd use a minimum radius of an 1/8th. There's a few lightening pockets that can't be cut on your plates, even with radiused corners.

If you're planning to mill the plates, it can be helpful to make the radius 0.126 inches. The extra thousandth makes generating the toolpaths a lot easier. That way, the machine doesn't have to go to a specific point, stop, and change direction; instead, it cuts the fillet as an arc.

I like the design. I'm guessing the upper shaft is .375 hex like the WCP shifter.

The wall thickness on your threaded holes is scary thin. A general rule is to use a circle that has twice the diameter of the hole. Also, the holes should be at the center of their fillets. It's stronger that way.

If you're really looking to save weight, you can get rid of the top set of standoffs and make the closer plate a lot smaller.
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