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Unread 01-31-2018, 08:38 AM
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Re: What is the best pocketing design for 2x1?

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Originally Posted by Brian M View Post
I'll second this pattern (or similar), I've used it a lot throughout the years and it's worked pretty good.

That said, this year my team opted to build a sheet metal drivetrain, and so to cut down on mill work we used a circle pattern on a number of elements so that the holes could be punched out using the our sponsors CNC punching machine. We're pretty happy with it so far.
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Last edited by cbale2000 : 01-31-2018 at 08:47 AM.
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Unread 01-31-2018, 11:34 AM
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Re: What is the best pocketing design for 2x1?

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Originally Posted by Andy A. View Post
Are you committed to that particular wall thickness?

2"x1"x.0625" aluminum tubing is available, and will probably beat the thicker material that's been trussed out in both weight and generalized strength, while also being cheaper and not requiring a whole lot of machining time.
Seconded
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Originally Posted by Knufire View Post
Use 1/16" wall. Add plates wherever you need more wall thickness, such as supporting a bearing.
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Originally Posted by Basel A View Post
This is the right answer in most cases. Immediately cuts out half the weight, with similar strength to pocketing, much much less work, and if you really need the thickness you can throw in a bearing block as needed.
Seconded

One of the driving reasons teams go over weight is not using 1/16th everywhere possible, it's almost always the better option in non-drivetrain parts.
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Originally Posted by Chris Hapstack View Post
We've had a heck of a hard time finding 2"x 1"x 1/16" in 6061-T6. Everywhere we've tried has been back-ordered for a couple weeks. Kind of unsurprising, given the elevator focus for many teams this year. Also to note, I called Vex and confirmed their 2" x 1" aluminum VersaFrame tube is out of stock until March.

We chose 1/8" wall 6061 instead of 1/16" wall 6063 as a second option. I haven't worked with 6063 before, but it's certainly softer. Does anyone have a source for 1/16" wall 6061? Or has had success with 1/16" wall 6063?
try contacting 973, they have worked to distribute the thin wall stuff fro Coast Aluminum here in California.

6063 is the devils aluminum. Sure it's more corrosion resistant, but that no help to us. Have fun deburring ALL your holes and cuts, frickin' cheese-grade I tell ya.
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Unread 01-31-2018, 08:19 PM
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Re: What is the best pocketing design for 2x1?

Thanks for the recommendations, everyone - 973 has some available.
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Unread 02-01-2018, 02:12 AM
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Re: What is the best pocketing design for 2x1?

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Originally Posted by RoboChair View Post
try contacting 973, they have worked to distribute the thin wall stuff fro Coast Aluminum here in California
Coast was out of stock last I checked, so it's triangle season on 5940 .
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Unread 02-01-2018, 02:13 AM
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Re: What is the best pocketing design for 2x1?

http://www.wcproducts.net/aluminum-tubing

Also have misc tubing including 2x1x.0625 available here.
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Unread 02-01-2018, 07:24 AM
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Re: What is the best pocketing design for 2x1?

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Originally Posted by RoboChair View Post
... One of the driving reasons teams go over weight is not using 1/16th everywhere possible, it's almost always the better option in non-drivetrain parts...
+1

2587 built most of their 2015 robot out of 1/8" wall 2x1 and 1x1 by mistake. It was probably similar in size to what you are building. We spent most of a weekend with two hole saws and many deburring tools to "add lightness". At least we didn't have to put that on the BOM
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Unread 02-01-2018, 09:54 AM
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Re: What is the best pocketing design for 2x1?

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Originally Posted by frcguy View Post
Coast was out of stock last I checked, so it's triangle season on 5940 .
We just took a shipment on monday of 260 feet of .063 wall 2x1. I would call again and see. They were back ordered but we got our delivery this week. It only took them 1 week to fill the order.
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Unread 02-01-2018, 12:36 PM
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Re: What is the best pocketing design for 2x1?

I like to use 0.0625" wall material when possible. But when wall thickness and light weight are both design requirements, I like to pocket part way through the material, and use large triangles. It's fast to cam and cut, it retains a lot of strength, and it looks nice. Attached is a picture of an example.
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Unread 02-01-2018, 12:43 PM
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Re: What is the best pocketing design for 2x1?

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Originally Posted by Bryce2471 View Post
I like to use 0.0625" wall material when possible. But when wall thickness and light weight are both design requirements, I like to pocket part way through the material, and use large triangles. It's fast to cam and cut, it retains a lot of strength, and it looks nice. Attached is a picture of an example.
Nice. Very nice.
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