Direct Drive #219 Pitch Monster Sprocket

Here is a link to look at the properties:
http://www.onlinemetals.com/plasticguide.cfm
delrin is at the top....polycarbonite is down at 1/2 page.
& the clear would look.....well invisable LOL

If any one really wants to try one of these pm me for pricing.
 
There are a few that look like they would fit the bill mechanicly.

I have purchased odds & ends from that site.
cost for materials minus shipping to me.
.187"t x 24" x 24" plate stock

Delrin -$68.72
polycarbonite-$30.70
nylon $76.00

(thud is a notorious cheap sk8!)
 
I asked Mclovin to draw up that CAD for us, I think he did an excellent job, thanks man! I am ordering some aluminum off eBay for about the same price as that polycarbonite Thud has suggested. Anyone ever heard of 7475 aluminum? It seems to be high quality but might need hardening, it's a type O temper. Anyway, I should have it over at my buddy's shop by next week, so whenever he can fit it in, I'll have pics. If only I could have gotten more people onboard, it would have saved me alot of time and headache just to have Azusa Engineering make us a batch. It would be cheaper too. Oh well, everyone has there own idea of what they want, so it's hard to unify an order like this.

Polycarbonite sounds really cool Thud, would it be able to take the forces exerted on it if it was mounted to the disk brake bolts on a hub? Maybe use nylon inserts to absorb some of the shock? What about flexibility? Will we néed to mount it to a fairly large diameter flange in order to work around this?
 
McLovin-

Your location says you're local to me.

I just tonight got my CNC all working. :)

But I don't know jack squat about CNC anything. :( So I'm frantically trying to learn as I go. :)

It seems you're handy with the code and design stuff that I badly need some help with. :)

My machine can take in sheets 24" wide, and as long as can fit in the room. It has a cutting area of 13.5" x 26.5". I bought a load of various end mills in all sizes and types.

My machine is supposed to be accurate to roughly 0.005", which seems like it would be good enough for making a plastic sprocket.

I would be happy to buy a stack of suitable plastic sheets, pick you up and take you to my place, and we could get things figured out to get me making some sprockets. :)

20100201170038.jpg

20100202203942.jpg
 
Right on Luke,

looks like a nice little setup. What did you purchase if you don't mind?
I'm ready to sell my truck to free up some money!

etard,

Fully annealled (temper O) is probably a bad idea for a sprocket. you could have it hardened buy why?
IMO, it would be easier to buy T6 temper and machine it.
 
Luke,
what is your controller? (Mach3?)I can e-mail you programs to try it out. Let me know T
 
12p3phPMDC said:
Right on Luke,

looks like a nice little setup. What did you purchase if you don't mind?
I'm ready to sell my truck to free up some money!

etard,

Fully annealled (temper O) is probably a bad idea for a sprocket. you could have it hardened buy why?
IMO, it would be easier to buy T6 temper and machine it.
Click to expand...


Contact ES member Kburn77. He was kind enough to specially build me this machine. It's made as his house in Arizona, and I think it's one of the first made in USA devices I've bought in years, and I couldn't be happier about every part of the buying, shipping, and support he has given a CNC newb like myself. :) Everything you see in the picture there is under $2,000. :)



Thud said:
Luke,
what is your controller? (Mach3?)I can e-mail you programs to try it out. Let me know T
Click to expand...

Thud- It is setup to run with Mach3, and I will run any code you want me to try that fits in my 13.5" x 26.5" x 6" cutting area. :)

As far as materials go, I've got a few sheets of 4mm and 6mm thick carbon fiber in 20x40" sizes. :) A carbon fiber sprocket would be pretty slick looking, but the sheets weren't cheap. :(
 
mmmmmmmmmmm transparent monster sprockets, awsome.
i need a 219 165t lol :mrgreen:
etard, Mclovin did indeed do a fine job, do you understand the guys guide to materials?
composite or some such would be lighter and easier to machine swirly cut outs? let me know what you think.
great looking piece of kit btw Luke.

D
 
D- If you want to buy some 5mm carbon fiber sheet

Fairly cheap one here that isn't finished to look pretty:
http://dragonplate.com/ecart/product.asp?pID=4088&cID=97

I don't remember if the OD of the sprocket needs to be over 12x12.
 
etard said:
Anyone ever heard of 7475 aluminum? It seems to be high quality but might need hardening, it's a type O temper.

Polycarbonite sounds really cool Thud, would it be able to take the forces exerted on it if it was mounted to the disk brake bolts on a hub? Maybe use nylon inserts to absorb some of the shock? What about flexibility? Will we néed to mount it to a fairly large diameter flange in order to work around this?
Click to expand...

Be carefull of "0" temper. it could mean that it is dead soft OR that it has not yet be mechanically stress relieved. I suugest looking here: http://www.matweb.com/.

Also, beware of UHMW and polycarbonate for anything that is a wear surface. I use to use that stuff in designs to support chain and belt. What use to happen is that small bits of grit would get pushed into the material (very low hardness compared to steel) and build up to the point where it would become very abrasive and cause the belt or chain to wear out much faster. Maybe it won't be a inssue in this application...I dunno. Have you ever looked into a mterial called PEEK. It may be worth a look (it's plasticy).

Liveforphyisics: I'm actually enroute to China for a couple months but I'd be happy to try and set up a remote web session and have a look at your CNC programming setup. Let me know. I can create a GoTo account for free for 30 days and use it to remote into you PC (the one hosting the CNC software).

Cheers.
 
Luke,

i think the 165t we're after is 16" diameter :shock:
This is why im keen not to have a solid ally monster, more a slick stealth sprocket with as little material as possible.
What would be very cool if it were cut to give a spoke look but obviously it needs to be ultra rigid, mounting to the sickbikes you did for me it has a loooong way to the outer edge.
That sheet isn't too scary on cost i wonder if they do a 16" sq. sheet - im up for any suggestions on material here???

D
 
deecanio said:
Luke,

i think the 165t we're after is 16" diameter :shock:
This is why im keen not to have a solid ally monster, more a slick stealth sprocket with as little material as possible.
What would be very cool if it were cut to give a spoke look but obviously it needs to be ultra rigid, mounting to the sickbikes you did for me it has a loooong way to the outer edge.
That sheet isn't too scary on cost i wonder if they do a 16" sq. sheet - im up for any suggestions on material here???

D
Click to expand...


Hmm... Lemme look through my CF pile... ;)

cfmeasurement.jpg


cfsheetedge.jpg


I have a sheet that is 32 plies of aerospace grade carbon fiber here... 16" wide x 31" long x 0.23" thick...

But, this sheet is earmarked to become the rotors for my motor, not a sprocket. :) Even if the wear is an issue, I've got 1/4" lexan sheet in 48x48" sizes laying around. I could make and send a few of them, then if they don't last long enough, or if they eat the chains or whatever, we could try a new material. It's not like you've gotta pay an expensive machine shop for time on a CNC or something, so it only costs materials to try new types. ;)
 
If you're wanting lexan, buying a sheet like this:
http://cgi.ebay.com/1-4-polycarbonate-sheet-clear-OptiClear-48-x-32_W0QQitemZ360181151669QQcmdZViewItemQQptZLH_DefaultDomain_0?hash=item53dc7837b5

Will bring the materials cost down to $16.50 sprocket to do the strongest of the clear plastics, lexan. This would make it look kinda like there was no sprocket on the bike, and just a loop of chain wrapping around air.

Here is a sheet in black ABS for $21

http://cgi.ebay.com/1-4-ABS-plastic-sheet-car-interior-16-x-16_W0QQitemZ200394819583QQcmdZViewItemQQptZLH_DefaultDomain_0?hash=item2ea87647ff
 
liveforphysics said:
McLovin-

But I don't know jack squat about CNC anything. :( So I'm frantically trying to learn as I go. :)

It seems you're handy with the code and design stuff that I badly need some help with. :)
Click to expand...

You need a CAM program. For 2.5D I use SheetCam and I hear CamBam is good. 3D stuff is another story. These tend to be expensive. Found one called FreeMill that was free but rather limited in what it can do.

For test cutting I use the blue or pink insulating foam that you get from Homedepot.

I have a program that generates gcode for sprockets that I think someone here posted on another thread. Let me know if you need a copy.

A vac system to keep the dust at bay is the first thing you should add.

Bubba
 
dontsendbubbamail said:
liveforphysics said:
McLovin-

But I don't know jack squat about CNC anything. :( So I'm frantically trying to learn as I go. :)

It seems you're handy with the code and design stuff that I badly need some help with. :)
Click to expand...

You need a CAM program. For 2.5D I use SheetCam and I hear CamBam is good. 3D stuff is another story. These tend to be expensive. Found one called FreeMill that was free but rather limited in what it can do.

For test cutting I use the blue or pink insulating foam that you get from Homedepot.

I have a program that generates gcode for sprockets that I think someone here posted on another thread. Let me know if you need a copy.

A vac system to keep the dust at bay is the first thing you should add.

Bubba
Click to expand...


Thank you for the tips. :) I'm experimenting with a program called LazyCAM at the moment, and so far I've just completed my first successful dry run with the machine. I didn't even turn the spindle on, just ran it through the steps of what it would take to cut out my name "Luke" with 40mm tall fancy letters 1cm deep, and it seemed to run through everything in a well behaved manor. :)

Quite honestly, the whole process of CAD'ing my name, loading it in the lazyCAM, setting up the tool dimensions, and running the thing was pretty easy to stumble through for the first time, and now I think I could repeat all the steps and have it cutting out anyones name in maybe 10mins, counting the time to fix a block of something rather in the machine. :)

I'm still in awe of how amazing this is to have something that can cut things out for me, and to do a good job at it! I'm almost freaking out over how cool it is to watch the tool move in the needed ways to create what I want.

The ability to shape material like this is like something I've only experienced in my dreams. It hardly even feels real!

:) :) :) :)
 
Luke, If you Have RhinoCam in you software pakage, you have a very nice version of Visualmill 6.0 (by MecSoft) Its what I program our 3 big routers at the shop with. MecSoft is the maker of the crippled "freemill" version.
(it works but you only get 2-1/2d code from it & only 1 machining stragity,from solid model parts)

I haven't sketched much in Rhino but It should be more than you will ever need to draw a single part with. Parametrics are nice if you are designing complex machinery with mutiple parts & assemblies.

now on topic:
Lukes machine will only cut a 135t sproket.
I am getting a price quote for .187"t lexan sheet from my local suplier.
That will yeild 18 159t sprokets.
I don't like the tight bolt pattern of he ISO disc mounts or even the 67mm BCD of the eno's
I think the 6 hole 5.25" BCD go cart sprocker adapters are an acceptable compromise in aluminum.

Senario=broached sic bikes adapter on free hub, Sic bike 2 go-Kart adapter, lexan sprocket.
like this....who wants to be the test pilot?
159stealthsprocket.jpg


Etard, pm me an e-mail address & I will send you the .dxf of these parts. (your machine guys will take it from there)
 
Miles,
I can only see the machine in the photos above. The 13.5" width (I assume Y axis) is the constraint.
Not sure if luke can get the 16.25"+ he would need for 165t sprockets, re-configuration is allways an option.

I am sending luke some code for the aluminum sic freewheel adapter generated on a post-prosessor I am writing for his machine.
I have a couple of questions regarding machining stragitys & the way to address tool changes on these small single spindle machines. (any thing is possible :D )

Luke, I am pretty sure Rhino will open the .vcp formats from mecsoft. I will include these for you to play with.
 
Thud said:
Miles,
I can only see the machine in the photos above. The 13.5" width (I assume Y axis) is the constraint.
Click to expand...
He was talking of getting a 4th axis. Would that allow pretty much any diameter sprocket to be cut (within reason..)?
 
I dug through my scrap bin, and found a 1/4" x17 x 24" sheet of lexan :) should be just enough to get 2 sprockets :)


The width of the cutting table is 24", so this is my ultimate limit for a part, and I can only cut 13.5" in the middle of that 24" area, so to cut something at 24" it would need to be moved after half the cutting and perfectly positioned to run the same code again over the part. With something like a 24" x 24" square of material, and a jig, it doesn't seem like this wouldn't be too tough though.

I am shopping for a 4th axis right now, but the plan was to mount it under the table as a vertical plane 4th axis for doing cutting on the outside of round objects, rather than horizontal plane. I bet it wouldn't be much tougher though to make it so it dual mounts in either position. :) I would still have the 24" limit though.
 
I think your imagination would be the only limitation.
A configuration to turn the part radialy would allow for some large radius parts. A simple primary operation to get holding points for 2ndary machining would be required.
Fixturing is allways the key for these things.
Proper fixtures & indexing would eliminate the need for a cnc LOL......but that computer makes things soo much faster!
 
OMG! It's carving!!!! Its carving!!! Yes!!!!!!!!

It's writing "Luke" in a scrap of 2x4. :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :) :)
 
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