Hubs Manufacturing Plan

Final Geometry: 24-DYN-2201-R7 (Hub)

Link to Sims: Hub V6

Stock (metal supermarkets): Aluminum Round Bar 6061 - Metal Supermarkets

• the largest OD on hub is 5.14 in

  • next OD size is 5.25 inches

• hub length = 2.83in

  • can choose any length required; good to make it 2.9 in

• quote: $87.06 per hub

Tooling Needed:

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Rough machining plan:

• the hub has 5 distinct OD you need to achieve on the lathe, however you want to add an offset (of 20 thou) to 4 of the 5 OD’s for 3 reasons

  • 1: it ensures that you don’t go close to nomial and undersize your OD by accident bc

  • 2: CNC is more accurate than lathing by hand and can achieve precision to a higher degree than we can, so all critical dimensions are done on CNC

  • 3: for the OD between the rotor and rim connection, no because there are structures surrounding it, no tool can clear that, so you need to get that to nomial on lathe

• the hub also has 4 distinct OD’s however to save time, just use a drillbit that is one size smaller than the smallest OD and drill a through hole throught the hub, don’t waste time boring the CNC can make the distinct OD’s faster and better than you can

Op 1: Outboard Side (rim seating and rotor flange)

• Workholding:

  • Measure the distance of the actual parts

    • 1.19 in, so you want to add a .1 inch margin to how much you hold it down (what this means is 1.19+0.1 = 1.29 inches of exposed material should be exposed

    • since the hub stock is 2.9 in long, clamp 0.96 inches

    • indicate and get concentric

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• Major Diameter:

  • nominal is 5.14 + 0.02 (20 thou) = 5.16

  • stock is 5.25 - 5.16 = 0.09 to take off

    • do 1 pass at 0.01 step down to make sure the setup is good

    • do 2 passes at 0.04 step down to get to nominal + padding

    • 800 rpm, .004 feed rate

• Minor Diameter:

  • nominal: 3.7 + 0.02 = 3.72

  • needs to be .89 in long, but the MD one needs to be .3 in long = .89+.3 = 1.19

  • we have 1.29 in of material stick out, do 2 to 3 passes cleaning up the stock end of the plate (don't go more than .05 inwards)

  • the OD rn is 5.16in, normal + padding is 3.72, diff = 1.44in

    • start small with passes, 30 thou then you CAN work up to like 100 thou, just be careful with vibrations all

    • make the length of cut .89in (EXACT) but its not the end of the world, leaving more material is better than leaving less material.

  • 800 rpm, .004 feed rate

• Bore:

  • smallest ID = 1.96in

  • we will do a 2in hole, but you can’t just do that so:

    • center drill

    • 1/4 in drillbit

    • 1 in drillbit

    • 2 in drillbit

  • 540 rpm

  • drill the entire way through the part

Op 2: Inboard side:

• Workholding:

  • clamp onto the minor diamater from the outboard side

  • indicate

• major diameter = 1.92 + .02 = 1.94 in

  • turn down to this