Go to Post If you smack the bear with a stick, you'd better be ready for a mauling. - sciguy125 [more]
Home
Go Back   Chief Delphi > FIRST > General Forum
CD-Media   CD-Spy  
portal register members calendar search Today's Posts Mark Forums Read FAQ rules

 
Reply
 
Thread Tools Rate Thread Display Modes
  #1   Spotlight this post!  
Unread 06-10-2016, 16:45
Cothron Theiss's Avatar
Cothron Theiss Cothron Theiss is online now
Registered User
FRC #4462 (Full Metal Jackets)
Team Role: College Student
 
Join Date: Feb 2016
Rookie Year: 2013
Location: Kingston, Tennessee
Posts: 499
Cothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant future
Re: Q. Best sheet metal design?

Quote:
Originally Posted by InFlight View Post
If your bending 0.125" sheet you will definitely need to have a larger bend radius on your sheet metal brake to not induce stress cracking.
From my experience, teaching students to bend and/or weld .125" and especially .25" 6061 is pretty difficult. If your design requires tighter bends and welding at some point, I would stick to 5052. 5052 is a great alloy to teach students to weld on, and if you outsource your welding, some shops will charge less for the easier allows to weld due to the different costs of filler materials. (This is probably a case-by-case thing, so it's just better to ask.)
If your frames won't include many complex bends or require minute and difficult welds, 6061 is an amazing alloy.


EDIT: A complete aside, but teams 2024, 5052, and 6061 are missing out on some of the coolest potential team names ever. Whoever becomes team 7075 has a great opportunity.
__________________
"It's taking longer than expected, which was to be expected."

Last edited by Cothron Theiss : 06-10-2016 at 17:05.
Reply With Quote
  #2   Spotlight this post!  
Unread 06-10-2016, 18:04
InFlight's Avatar
InFlight InFlight is offline
3574 - The King's of Bling
AKA: Jim
FRC #3574 (High Tekerz)
Team Role: Mentor
 
Join Date: Mar 2014
Rookie Year: 2012
Location: Seattle Area
Posts: 163
InFlight is an unknown quantity at this point
Re: Q. Best sheet metal design?

Quote:
Originally Posted by Cothron Theiss View Post
From my experience, teaching students to bend and/or weld .125" and especially .25" 6061 is pretty difficult. If your design requires tighter bends and welding at some point, I would stick to 5052. 5052 is a great alloy to teach students to weld on, and if you outsource your welding, some shops will charge less for the easier allows to weld due to the different costs of filler materials. (This is probably a case-by-case thing, so it's just better to ask.)
If your frames won't include many complex bends or require minute and difficult welds, 6061 is an amazing alloy.

.
Bending .125 or .250 sheet with a tight bend radius is a bad fabrication detail; the effects of which will be more apparent with higher strength 6061.

There really isn't any appreciably difference in the cost of ER4043 or ER5356 filler for 5052 and 6061 respectfully. Good welding takes considerable practice however; and does not appear to be a common skill with most high school students. The over focus on performing well on standardized tests has eliminated most shop class options in the middle and high schools.

We avoid welding aluminum if possible. We fully CAD, water-jet the aluminum sheet, bend, and rivet. You can replace a riveted assembly; you can't take apart a welded assembly. Pneumatic riveting through a series of water-jetted holes is also significantly faster than setting up for a single weld.
__________________

Thank you 2016 Alliance Partners - 948, 1510, 2046, 2521, 2980, 2990, 4911, 4683

Last edited by InFlight : 06-10-2016 at 18:14.
Reply With Quote
  #3   Spotlight this post!  
Unread 06-10-2016, 18:51
Cothron Theiss's Avatar
Cothron Theiss Cothron Theiss is online now
Registered User
FRC #4462 (Full Metal Jackets)
Team Role: College Student
 
Join Date: Feb 2016
Rookie Year: 2013
Location: Kingston, Tennessee
Posts: 499
Cothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant futureCothron Theiss has a brilliant future
Re: Q. Best sheet metal design?

Quote:
Originally Posted by InFlight View Post
There really isn't any appreciably difference in the cost of ER4043 or ER5356 filler for 5052 and 6061 respectfully.
I'll have to ask one of the machine shops I've sent parts to about why they quote 5052 welding services as cheaper than that for 6061. I'm honestly not too sure about it.

Quote:
Good welding takes considerable practice however; and does not appear to be a common skill with most high school students. The over focus on performing well on standardized tests has eliminated most shop class options in the middle and high schools.
Isn't that why we're here? Quality shop classes are becoming a rarity in high schools and FRC is able to, in the right situations, fill the void and educate students.

Quote:
We avoid welding aluminum if possible. We fully CAD, water-jet the aluminum sheet, bend, and rivet. You can replace a riveted assembly; you can't take apart a welded assembly. Pneumatic riveting through a series of water-jetted holes is also significantly faster than setting up for a single weld.
I think this is a matter of resources. My team does not have access to a water-jet. My team does have a mentor that's been welding aluminum for 30 years and loves nothing more than to pass on his craft. I don't know if the OP intends to weld some of the joints in his drivetrain, but I thought I'd include the information anyhow.
__________________
"It's taking longer than expected, which was to be expected."
Reply With Quote
Reply


Thread Tools
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

vB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump


All times are GMT -5. The time now is 01:00.

The Chief Delphi Forums are sponsored by Innovation First International, Inc.


Powered by vBulletin® Version 3.6.4
Copyright ©2000 - 2017, Jelsoft Enterprises Ltd.
Copyright © Chief Delphi