FlexCar Gear Set

thingiverse

For the latest design, I transformed Flexbot into FlexCar, and this time I designed the gear set from scratch using computer-aided design software and manufactured it through three-dimensional printing technology. The motor spins at an incredible pace, requiring a significant reduction in speed to achieve optimal performance. To accomplish this feat, I incorporated a gear set with a speed-reducing ratio of 1:52 into the overall system. The dimensions of FlexCar are as follows: length is 59 millimeters, width is 77 millimeters, and height stands at 20 millimeters. To bring this project to life, you will need access to certain materials and equipment. Fortunately, many of these can be found in a typical household environment. The printer utilized for this endeavor is an FDM three-dimensional printer, which relies on PLA filament for its prints. The settings employed include layer thicknesses of 0.15 millimeters and extruder diameters measuring 0.55 millimeters. To create the gear set's core shafts, I employed common rivet cores with a diameter of 2 millimeters and chopsticks with a diameter of 5 millimeters. Additionally, two metal axles with internal diameters of 5 millimeters, external diameters of 10 millimeters, and heights of 4 millimeters are required. A lubricating oil is also necessary to facilitate smooth operation. To my delight, the gear set performed admirably upon completion. However, due to the limitations inherent in three-dimensional printing technology, the accuracy was not sufficient, resulting in an excessive amount of noise generated by the gears as they moved, resembling the sound produced by an impact drill drilling into a wall. The smallest motor used in conjunction with the core-less motor features a magnetic permeability coefficient (m) of 1 and an electrical conductivity (z) of 7. The installation diameter of the axle is 1 millimeter, leading to frequent slips between the gear and axle. If you have any ideas or suggestions for this design, I would greatly appreciate your input so that I can further refine it. You can view our FlexCar gear set on GrabCAD at https://grabcad.com/library/flexcar-gear-set-1. Print settings employed include: * Rafts: Yes * Supports: Yes * Resolution: 0.15 millimeters * Infill: Solid