Quote:
Originally Posted by squirrel
What would happen if you tried to use a smaller hex for the central hub?
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Not sure. Next time I boot my Mac into windows to do some CAD, I'll throw together a different version with smaller hex. But to be honest, I'm not sure I'd feel comfortable making it any smaller. The team I'm mentoring has an affinity for Banebots transmissions, so I think the goal is to keep to wheels that can be direct driven off a BB tranny.
Quote:
Originally Posted by JesseK
For even less necessary machining, you could not mill out the inside of the hex stock, and instead thread-tap the holes where the counter-sunk screws go in. This makes it a bit heavier, but you wouldn't need a mill to make the wheel.
Then, you could also drill the KOP hub bolt-circle pattern into the side, eliminating the necessity of having to make a key way.
To take this even further, instead of counter-sunk screws you could use half-head-height machine bolts, eliminating the need to create the extra dimple after the initial hole is drilled.
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There are definitely many revisions that could be made to seriously reduce machining time, but this is really just a 1.0 wheel. I'm debating changing the milling operation on the hex to be entirely one sided, so the "dishing" of the wheel would be done in a single Mill op. I'll have to do some FEA tests to see how the strength would stack up.
Also, for the rough ride concerns: Once I make the wheel wider, and thus the rollers longer, the wheel actually smooths out a good bit.