Fabricating Aluminum Sprockets

[Dick Linn]

I would not recommend plasma cutting because it will affect any heat treating and it will laso not leave a smooth surface for the sprocket teeth.

[FourPenguins]

We've done custom sprockets on a CNC router with great success, so I'd say just do it on a CNC mill or router and find another project to mess around with your new plasma cutter.

[Elgin Clock]

Originally Posted by Andrew Blair

Talk to RAGE. Their 2005 bot had a massive #35 er that they did.

I'm not positive, but I'm assuming (always a bad thing, I know) that since one of their sponsors is CNC Software (maker of MasterCAM) they may have had a little inside help there. It's always good to have connections in the industry.

[Aren_Hill]

Originally Posted by Elgin Clock

I'm not positive, but I'm assuming (always a bad thing, I know) that since one of their sponsors is CNC Software (maker of MasterCAM) they may have had a little inside help there. It's always good to have connections in the industry.

i was at the International manufacturing tradshow at mccormick place chicago
and i went to the master cam booth and started talking to him i said say your team # i'll tell you your name he said 273 which i didn't know off the top of my head i then asked his team name he said rage i then corrected him of his actual team # of 173 and started describing there robot in very close detail. but he was there lead cnc guy i think

i also saw Dan Larochelle and several of 40's vex robots and a small cnc mill whirring away and talked with him.

its amazing what a small world this is

and is there a specific program for easily making #25 sprockets on a cnc mill
because i need some for an offseason project and have plenty of time

[D.Fahringer]

Originally Posted by Gear

and is there a specific program for easily making #25 sprockets on a cnc mill
because i need some for an offseason project and have plenty of time

I think you might want to download this shareware program called "Machinists Mate" Ver. 4.1 from www.wadeproco.com ...Along with other machining wizards you will see an icon for a sprocket DXF generator in there that works pretty well! It will generate one tooth valley that you can use to create your toolpath either by copy and rotate in CAD or a sub-routine that will achieve the same thing on your CNC mill. I am glad this question came up, I have always had my CAD method for generating sprocket cutting programs but this calculator will be much faster!

[Qbranch]

Originally Posted by M. Krass

We're interested in possibly producing ANSI #25 pitch sprockets from aluminum. We have a plasma cutter, so cutting the tooth profile ought not to be too difficult.

I have vague notions of processes like heat treating, but no real experience with the craft; nor have I ever heard that sort of thing discussed with respect to aluminum.

Does anyone have any experience with the process of making your own sprockets from aluminum that might also have some tips to share?

Thanks.

I have done this several times on a CNC mill using an 1/8" end mill... should be able to be done on a Live Tooling equipped CNC Lathe too...

if the sprocket's big enough, heat treating now necessary.

the thing i suggest is after completeing the sprocket profile, chunk it in a manual lathe put the slight bevel on both sides, but very very slight. also takes care of most the deburring.

PM me if you have any more questions.

-Q