Rotor machining fixture

After getting the stator out of its housing, the next step is to do the post-machining on the rotor.  Here, I didn’t want any of the original bearing housing, and just needed to drill out a hole in the middle big enough to put my sun gear holder through.  I figured I would experiment with some custom fixturing, so broke out Fusion 360 and drew up a set of “soft jaws”… i.e. *really* soft jaws, since they would be 3D printed.

Rendering of rotor fixture
Rendering of rotor fixture

I printed these on my Prusa MK3s, at 60% infill in PETG, then mounted it up on a vise in the drill press.

Rotor mounted in fixture
Rotor mounted in fixture

I ended up needing to get an even bigger drill bit than the biggest I had, and took a few passes with progressively larger bits, and it was still slow going.

Beginning of 5/8" bit pass
Beginning of 5/8″ bit pass

Despite that, I managed to mess up my English / Metric conversions and the hole still wasn’t big enough, so I had to go at it with a dremel to finish it off.  However, now the sun gear holder does fit in nicely!

Rotor with sun gear, inside view
Rotor with sun gear, inside view
Rotor with sun gear, back view
Rotor with sun gear, back view

4 thoughts on “Rotor machining fixture

  1. I like the idea of the 3d printed fixture; might have to try that in the future. What did the inside/shaft part of the rotor look like prior to machining? Hard to tell from dys.hk’s images/drawings on their site

    Like

      1. Cheers! Makes it a lot easier to model, considering mine are still being shipped 🙂

        Like

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out /  Change )

Google photo

You are commenting using your Google account. Log Out /  Change )

Twitter picture

You are commenting using your Twitter account. Log Out /  Change )

Facebook photo

You are commenting using your Facebook account. Log Out /  Change )

Connecting to %s