Frage Electric motor assisted bike mount

Mock up. Part of a bracket for electric motor assisted bike milled from laminate flooring.
https://instagram.com/p/x9wL5fg0Ue/




Rounding off the corners. Aluminium plate to mount an electric motor.
https://instagram.com/p/yNDrkNg0a0/




Electric motor assisted bike indoor test run controlled using a cheap servo tester. Test went very well. Well chuffed.
https://instagram.com/p/yju6jig0RL/

Yiiiikes. STEPCRAFT V1... and proxxon...

ReSpeCt!

Notice the holes used to clamp the middle of the work. Very secure (tool makers jig type) clamping. Minimal vibration. Looks great on the finish front also

Nice work!

What cutting tool did you use?

It was roughed out and holes drilled on a manual bridgeport machine,then with my Stepcraft I milled two locating holes in for the big bolts, which I used to line up the job ready for profiling.

I used a 3mm Dia ,two fluted solid carbide slot drill to mill the profile.
RPM approx 10000
Feed rate 100 mm/min
Depth of cut 0.25mm

I used those settings as it was cutting on full width of cutter at the start of the rads.
I haven't milled aluminium on the Stepcraft until now, it seems ok cutting the profile and I know I could have increased the feed rate and depth of cut.
My Stepcraft isn't happy at plunging into aluminium so I made sure I had a lead in from out side of the profile.

Oh don't cut aluminium dry, as the chips/swarf can weld itself to the cutter and prevent it cutting and possibly break the cutter, I used a little sewing machine oil, but a squirt of wd40 or anything light would do.

blanthegenius schrieb:
Oh don't cut aluminium dry, as the chips/swarf can weld itself to the cutter and prevent it cutting and possibly break the cutter, I used a little sewing machine oil, but a squirt of wd40 or anything light would do.

Probably this depends on the kind of aluminium you cut. I cut all aluminium dry so far, without problems.

also - watch out WD40 has a flash point! So don't let it get hot...!!

Often best to have airline / some cooling...

free cutting aluminium block machines much easier than rolled plate ali. But even still you have to be careful..

plunging into Ali puts the most pressure on it! best to ramp plunge or be careful how you approach the cut.

really impressive results!

MagIO2 schrieb: Probably this depends on the kind of aluminium you cut. I cut all aluminium dry so far, without problems.

So the obvious question: what kind of aluminium do you cut dry MagIO2?

This build can also be seen over at instructables.com please go check it out.

Very nice craftsmanship. Isn`t debris going to cause problems when getting into that open motor casing?

thanks tikka,

It's been on for about 3 months now and I've not had trouble with motor clogging up with debris as yet, I can't say I've noticed any difference in performance.