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Custom machined #25 40 tooth aluminum sprocket. One piece construction and tapped bolt holes eliminate the need for spacers, nuts and allows for shorter bolts.
Discussion
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26-07-2007 21:01
AdamHeard
Re: pic: Custom Machined Aluminum #25 Sprocket
Looks nice... These were in the drive I assume.
How long did it take to machine? How many set ups? (I'm assuming one on a CNC mill and one on a waterjet/lathe)
do you know if the amount of weight saved (how much did it save?) was worth the extra time?
26-07-2007 21:09
Holtzman
Re: pic: Custom Machined Aluminum #25 Sprocket
Machining time was a little over an hour. 1 setup on the mill. Holes were tapped by hand afterwards. Slight tooth chamfer was done on the lathe afterwards.
Was it worth the time? Probably not, but they do look nice.
26-07-2007 21:16
AdamHeard
Re: pic: Custom Machined Aluminum #25 Sprocket
Did you cut the teeth on the mill as well?
If so, what diamater cutter was used?
26-07-2007 21:26
Cory
Re: pic: Custom Machined Aluminum #25 Sprocket
Are those radiused areas in the center contoured?
Or do they just happen to be the same radius as a ball endmill you ran through there?
Those are some sick sprockets.
26-07-2007 22:04
Re: pic: Custom Machined Aluminum #25 Sprocket
Woah. I don't think I've seen a sprocket that sexy since one of 233's huge pink ones.... This one is just elegant though! It makes me wish more and more that my team had a CNC...
Nice job!
26-07-2007 22:16
Nuttyman54
Re: pic: Custom Machined Aluminum #25 Sprocket
two words: SICK NASTY!
190 had AL drive sprockets (31 teeth, I don't know why they HAD to be 31 teeth), but they were no where near as sexy as that beast...nicely done
26-07-2007 23:02
Jeff K.
Re: pic: Custom Machined Aluminum #25 Sprocket
Pretty snazzy!
Form does indeed follow functionality.
26-07-2007 23:07
sanddrag
Re: pic: Custom Machined Aluminum #25 Sprocket
What feedrate did you cut it at? That's a lot of material to remove just to avoid using spacers. But it does look quite nice.
27-07-2007 00:31
Jonathan Norris
Re: pic: Custom Machined Aluminum #25 Sprocket
TyTown those sprockets are absolutely ridiculous, I want one 
27-07-2007 08:55
alex1699
Re: pic: Custom Machined Aluminum #25 Sprocket
as Borat would say "Very Nice"
27-07-2007 13:30
JesseK
Re: pic: Custom Machined Aluminum #25 Sprocket
It wouldn't take much to cover the teeth and powder coat it for an genuine look either. Very nicely conceived, though I'm curious as to what a F.E. Analysis on it looks like. It looks at first glance as though the dips on the inner ring between the sets of holes would be the weakest points.
27-07-2007 13:36
AdamHeard
Re: pic: Custom Machined Aluminum #25 Sprocket
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Originally Posted by JesseK
It wouldn't take much to cover the teeth and powder coat it for an genuine look either. Very nicely conceived, though I'm curious as to what a F.E. Analysis on it looks like. It looks at first glance as though the dips on the inner ring between the sets of holes would be the weakest points.
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(this is just an assumption... If I had the model, I'd run FEA on it to verify)
27-07-2007 13:47
Greg Needel
Re: pic: Custom Machined Aluminum #25 Sprocket
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Originally Posted by AdamHeard
Probably true, but it looks to be atleast as thick as the standard sprocket thickness there. So, it is no weaker than a normal sprocket most likely.
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27-07-2007 14:24
M. Mellott
Re: pic: Custom Machined Aluminum #25 Sprocket
A beautiful piece--great job!!
I'd love to see an FEA analysis as well.
27-07-2007 22:22
Holtzman
Re: pic: Custom Machined Aluminum #25 Sprocket
Yes, the teeth were milled. Off the top of my head, I believe these are the operations we performed. It was a couple of months ago so the feeds and speeds might not be 100% accurate.
5/8" roughing endmill 1000rpm 4"/min roughs out tooth face and bore
1/2" ball nose endmill 1200rpm 2"/min put radius' around bolt holes
1/4" roughing endmill 1800rpm 2"/min roughs out medium sized pockets
1/4" plain endmill 2000rpm 6"/min finishes medium sized pockets and bearing bore.
1/8" plain endmill 2500rpm 1.25"/min mills small pockets, spot drills bolt holes, and outside sprocket teeth.
CAD files are available for anyone who wants them. As for FEA, if anyone wants to do it, go nuts.
27-07-2007 22:32
sanddrag
Re: pic: Custom Machined Aluminum #25 Sprocket
Wow, those feeds seem really slow. Must have taken a while. What machine were you using?
28-07-2007 01:04
Brandon Holley
Re: pic: Custom Machined Aluminum #25 Sprocket
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Originally Posted by sanddrag
Wow, those feeds seem really slow. Must have taken a while. What machine were you using?
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i'd say those feeds look pretty good to me, based on the machines i have used and the total size of the sprocket
28-07-2007 15:20
Gabe
Re: pic: Custom Machined Aluminum #25 Sprocket
Will the sprocket be anodized, or nicely buffed? (I'd tend to prefer buffing, since aluminum really works well)
06-09-2007 20:33
UlTiMaTeP
Re: pic: Custom Machined Aluminum #25 Sprocket
Would you mind posting the .dwg for this? You will be my BFF 
06-09-2007 21:46
Cory
Re: pic: Custom Machined Aluminum #25 Sprocket
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Originally Posted by Brandon Holley
i'd say those feeds look pretty good to me, based on the machines i have used and the total size of the sprocket
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I machine aluminum all the time at around 100 ipm (or even all the way up to 200ish).
Granted I believe 1114 has a small, benchtop CNC mill, which definitely isn't going to run like a VMC will.
10-09-2007 21:11
Brandon Holley
Re: pic: Custom Machined Aluminum #25 Sprocket
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Originally Posted by Cory
Seems really slow to me too.
I machine aluminum all the time at around 100 ipm (or even all the way up to 200ish). Granted I believe 1114 has a small, benchtop CNC mill, which definitely isn't going to run like a VMC will. |
10-09-2007 21:37
Holtzman
Re: pic: Custom Machined Aluminum #25 Sprocket
Corey's right. 1114 uses a small bench top CNC mill by RedCAM. Our coolant system consists of a freshman with a squirt bottle. We recently upgraded to a fish tank pump and a bucket. This was a vast improvement.
We've broken more than our share of endmills, and we try to extend tool life as much as possible, so we stick to slow feeds. It can be very time consuming, but student labor is cheap.
10-10-2007 07:50
Chief Pride
Re: pic: Custom Machined Aluminum #25 Sprocket
(old thread... but im going for it anyway)
what kind of mill did you use?
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