pic: Rough matches out there.

[wasayanwer97]

Originally Posted by Chowmaster4695

Just wondering, was there a reason your team chose to use plates and standoffs, as opposed to a more traditional approach using tubing? It seems like using plates and standoffs is more difficult to manufacture, potentially heavier, and significantly weaker. Just my .02$. Chow out.

I've been getting asked that all season.

As weird as it sounds, our machining resources for plate are far easier and more accessible than anything we could do for tubing. For us, this was far easier to manufacture and turned out lighter than tube would have been.

As for the last point, you're right. It is significantly weaker on the axis the drive train would take hits on. That's why when the front portion broke, the replacement was 2x1 tubing.

We're still extremely happy with the drive train, a game with defense as high as this one's was just definitely not the year to run it.

[JesseK]

Originally Posted by wasayanwer97

As weird as it sounds, our machining resources for plate are far easier and more accessible than anything we could do for tubing.

This isn't weird at all.

We tried to waterjet 4x2x0.125 tubing using PINK's method to only cut 1 side of the tube at a time, but the sponsor said they couldn't make it work on sample pieces. Luckily they had an in-house CNC and all it caused was 1.5 weeks of delay to get it done right.

[BBray_T1296]

Originally Posted by JesseK

We tried to waterjet 4x2x0.125 tubing using PINK's method to only cut 1 side of the tube at a time, but the sponsor said they couldn't make it work on sample pieces. Luckily they had an in-house CNC and all it caused was 1.5 weeks of delay to get it done right.

We use an aluminum cutting circular saw blade on a miter saw to slice our tubing (I think it is a $120ish blade). We used 1x1x1/16" and 1x2x1/8" tubing to build our frame.
We also use some cool corner stiffener inserts to keep the whole thing square. Our tolerances come to 1/32" with our most experienced student at work. The welding gives us the most tolerance troubles, but we are less than 1/16" everywhere

[JesseK]

Originally Posted by BBray_T1296

We use an aluminum cutting circular saw blade on a miter saw to slice our tubing (I think it is a $120ish blade). We used 1x1x1/16" and 1x2x1/8" tubing to build our frame.
We also use some cool corner stiffener inserts to keep the whole thing square. Our tolerances come to 1/32" with our most experienced student at work. The welding gives us the most tolerance troubles, but we are less than 1/16" everywhere

We use a horizontal bandsaw with automatic shutoff and plenty of cutting fluid to cut the pieces to near-perfect length. Then we tape all same-length frame members together so that they're flush on one end, and go to a wide belt sander. We sand one side of the taped tubes so it's square and the other side is sanded down so that all tubes are identical lengths. This year I think we were under 1/32" off, or basically less than a single tick of the tape measure. We then adjust CAD if necessary. We've become better at tolerances, so usually no CAD adjustment is necessary. While the welds have never been perfect (the rails always warp just a tiny bit) they're much better than we used to do.

I should have put that the waterjet/CNC was to cut mount holes & pockets into the 4x2 since it's so heavy.