pic: GT2 Pulleys

[DampRobot]

Originally Posted by JABianchi

I love the idea of making our own sprockets with a CNC mill, but have a couple questions for the more experienced:

(1) What's the best way to keep the sprockets from moving around on the last pass? (Especially if you are doing a tool change for finishing...) Are you using a vaccum table or another method?

(2) What's the easiest way to get the hex-shaped bore for the sprocket? Is the fillet from the CNC mill negligible or do you need to file or broach it after milling?

Thanks for any advice!

For the profile, I'd probably screw them down to a jig you hold in a vise, and then do the profile all in one pass. You already need holes to bolt the flanges on, so you might as well use them to hold the part down during the last op.