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Re: how thin is too thin?
Press fit, press fit, press fit or Loctite, Loctite Loctite!
This is a classic case for a press fit gear. We have been press fitting a gear on the CIM shaft since 2003. If you are nervous about press fit, then use Loctite 680. You can machine a pilot diameter all the way through your gear, then counter bore with a diameter slightly larger to take the Loctite 680. The Loctite web site has all the technical information you need.
To put your mind at ease regarding a Loctite 680 joint, FANUC Robotics (the company I work for) has a paint robot called the P-200. We have more than 1,500 of these robots installed in automotive paint shops all over the world. One of the the shoulder joint gears has a Loctite 680 interface and it never fails. This robot is designed for 10 year life running 16 hours per day, six days per week. It sees shock loading daily and holds up magnificently. My point is that a Loctite 680 designed joint will get you out of all your troubles for the least cost.
-Paul
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