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Sorry for the delayed response. Dislocated my knee and haven't been able to work on this project. I should have quite a bit of time to devote to it while I'm recovering from surgery... dinjin, Does doing what you're saying basically provide the tip relief that Terry mentioned?

Do making those profile mods require a custom cutting tool? The addendum mods are just changing how "deep" the cutter goes into the blank and not the profile shape, right?

I've now read the majority of AGMA 917-B97. That filled in quite a few holes. I need to check out the AGMA standard for getting my J geometry factor. I am also going to need to pay attention to my addendum modifiers. It looks like I'll have to add a bit to my pinions with my current tooth...

israelkk, It is true that I have little knowledge of the AGMA rating. This is my first experience in performing gear design so I am trying to go through the process slowly so I don't miss anything. I am becoming familiar with their strength formula and design factors. It is slow going...

Thanks Terry. Do you know where I can find material strengths as they relate to gear applications? I am trying to determine what face width will give me the strength that I need. The application is the gear train for a small RC type servo. The gears need to be 99.999% reliable as they will...

I'm working on a spur gear design and would like to get a rough check of the gear strength so I downloaded the Fairfield software and entered my data. I have a question on the material strength entries. I would like to use 17-4PH in an H900 condition so under Rating Stress for bending I have...

Thank you all for your input. I am now pursuing a modified DIN 912 solution.

Thanks Pud. Unfortunately, I don't think their fasteners are covered under a standard and they don't appear to be readily available. Thanks, Casey

I have searched the net and came up empty. I am looking for a M5 stainless SHCS, or hex head, with a cross drilled head for safety wire that is covered under a standard. I don't care which standard, ISO, DIN, etc. I found that the ANSI B18.3.1M standard has provision for a drilled head metric...

Picture of the nut side of the break.http://files.engineering.com/getfile.aspx?folder=2baf3ab9-7062-414c-8cc4-acb2c39e7695&file=Broken_Shaft-Nut.jpg

Desertfox, Attached is a picture of one of the failures. I don't have enough experience to be able to tell what type it is. The nut that is used is a custom nut made from 4140. It has an enlarged bearing surface with an area of 88.89mm^2. Something that I need to look into is the nut running...

Weight. The hub has a generator rotor pressed onto it so it already has a pretty good rotational mass. I have thought about seeing if the customer would be willing to possibly put a steel insert into the aluminum hub for the female taper. We have seen some pretty impressive examples of...

Thank you for your responses. I have attached a picture of the shaft. There is a woodruff key on the other side that we have found the hard way should only be used for alignment of the hub. We had several shafts break from torsional stress cracks originating in the bottom corners of the key...

The shaft is from an off the shelf 3W engine. The whole shaft is case hardened, including the threads, and then the bearing seats and taper are ground.

Would someone please point me towards some equations for calculating the required interference for transmitting torque through a 8620 case hardened tapered (11.5deg) steel shaft to a 6061-T6 aluminum hub? Can I just use the equations for cylindrical interference fits and pick either the large...

It is clear now. Thank you all.

The drawing is "correct" with the .010 perpendicularity tolerance. The folks who created this drawing are known for their GD&T funny business.

So the .056 hole doesn't shift relative to the shifted datum B? With that scenario, the .056 hole still has a .001 position tolerance with .002 bonus tolerance.

I have looked through ASME Y14.5-2009 and maybe I am blind, but I can't find what I'm looking for. Attached is an example drawing. How is the true position of the .056 hole affected by the MMC on datum B? The hole has a .001 tolerance zone at MMC, so I can get a little bonus tolerance if I...

We set the belt tension, as we are the ones building the assembly. The belt tension is determined by deflecting the belt a set distance and measuring the force required to do so.