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Originally Posted by Tytus Gerrish
arefin, what did i tell you about square holes?
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The thing about it is that it cannot be machined (by traditional methods). It is fine if you plan to laser or waterjet it but an endmill no matter how small will always have a radius. Another option would be some sort of custom broach, or machining it with a fillet and filing it square (not too hard and comes out pretty good if you use a nice sharp file).
Of course the easiest thing to do would be to just draw in a fillet and live with a filleted rectangular hole.
As for the lightening, I would recommend a pocketing pattern over a hole/cutout pattern. Even just .063-.090 of material left in the bottom of the pockets will add a lot of strength. Then you leave ribs of the full thickness. Sort of like this:
http://www.chiefdelphi.com/forums/sh...ad.php?t=34384
This keeps a uniform plate with no holes (which I think looks nice) that will be stronger than one with holes, but a very close if not the same weight.
Of course, it is all up to you and while it will be stronger without through holes, in this application it probably makes very little difference, when I see transmissions like the AndyMark running .090 plate with no problems.
I'm still curious as to how those dog gears spin on their turned down (to round) portions of the hex shaft.