Amarok Triple Clamp

grabcad

I have been watching this competition closely since it began and I have to say I am very impressed with the designs everyone has come up with! I have kept mine a secret until now and here is what I have to offer. Important Mass Information (see last screenshot for details) Mass: ≈ 816.31 g (820.64 g with M8 x 1.25 x 25 bolts) Centre of Mass (X-axis): = 0 to 8 decimal places Important Material Information Material: 6061-T6 (SS) Aluminum Yield Strength: 275 MPa Important Load Information 1340 N (≈ 301.24 lbf) force applied as worst case scenario (driver pulling down, as well as toward themselves and under heavy braking). Pulling down results in a maximum stress of ≈ 102.34 MPa and a maximum displacement of ≈ 0.85 mm. Pulling toward results in a maximum stress of ≈ 58.37 MPa and a maximum displacement of ≈ 0.37 mm. Heavy braking results in the same stresses as pulling toward the driver. I have uploaded a .eprt file of pulling down on one side. Important Machining Information I took the time to put this model into Mastercam X5 and it is simple to machine (all 2D toolpaths). Smallest end mill needed is Ø12 mm. Smallest ball nose end mill needed is Ø4 mm for milling outside. Use a small enough outside radius shape end mill with a 2 mm radius on top of the pocket and both sides of clamping holes. Use a Ø12 mm ball nose end mill on step with M6 threaded holes. Use a small 90 degree spot drill when chamfering the raised paw around the centre hole. Pocketing underneath has a constant 6mm fillet. With a 110 mm x 390 mm x 50 mm block, it should not take more than a few hours to set up the machine and cut the part (at least one fixture is needed for clamping). Depending on the CAM software, the model may have to be translated to a new plane (issue with SolidWorks trying to export properly). Additional Information All guidelines met with a simple, elegant and very rigid part. First file is .step and second is .igs. It would be interesting if a pad printer is available to print the logos (being a Canadian, I thought it would be fitting to incorporate our flag and Amarok's font on the front face. Rendering has black anodized material everywhere except where bottom features and other holes need to be shown. Good luck to everyone else in the running!