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Helical Cut Flex Coupling

phineasjw
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Published on February 27, 2012

Description

25mm Long 20mm Diameter. Now 5mm AND 0.25" (6.35mm) Bore files. I designed this for a light duty Z-Axis Nema 11 stepper (28BYG501) for a CNC engraver I am building.

I rounded all sharp edges for a professional appearance and to eliminate stress risers that could lead to cracks. Let me know if I missed any edges.

UPDATE - 3/3/2012: I added 3 new versions with a 1.5 turn helix cut. Mouse over file name and look for ones with 1pt5 at the end. Hopefully more robust. The originals were modeled after an aluminum one I had and I didn't account for the obvious material differences.

Instructions

I have not printed it yet as I am still anxiously awaiting my Makerbot Replicator.

I designed this in Alibre 3D CAD. I can add a generic 3D CAD file if anyone is interested in editing this - perhaps to change the end bore diameters to match your motor or rod diameter.

I put the slots and clamping nuts and bolts opposite each other to improve balance.

I included cutouts for a Boltdepot.com 3mm Jam Nut #13569.

UPDATE - 3/3/2012: I added 3 new versions with a 1.5 turn helix cut. Mouse over file name and look for ones with 1pt5 at the end. Hopefully more robust. The originals were modeled after an aluminum one I had and I didn't account for the obvious material differences.
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plexus on August 22, 2012 said:

Just printing a pair of these now at 0.1mm layers 100% fill. i want them strong. will let you know how it turns out

NM-Buzzard on March 8, 2012 said:

Thanks a ton, Good Sir!

Will try printing both the original and 1.5 turn versions later tongiht and report back!

on March 4, 2012 said:

Hi,

I tried this out in both ABS and PLA. They printed very well once I went to .3 mm layer height, with 50% fill and 2 shells.

Both have far too much angular flex to be useful, however, unless your load is close to zero. Might I suggest a helix of 1.5 times around, rather than 3.5 times around? I
think this might work pretty well in PLA.

Tonyv

phineasjw on March 4, 2012 said:

Thanks for the feedback on printing this thing.

I added the 1.5 turn version of the 5mm bore. Still getting the hang of doing this so it takes awhile to redo these. Seems like it should be easier till I start making the changes.

on March 4, 2012 said:

Soory, on my PLA part, it looked like the helix went 3.5 times around, but it is translucent, and tough to make out. I see from the model that it goes 5X around. I suggest trying 2X.

Tonyv

phineasjw on March 2, 2012 said:

The last file in the list is a modified coupling 25mm diameter, 5mm bore on one end and 3/8" on other end for NM-Buzzard. It was more of a tear up than I expected due to the large bore on one end.

Anonymous on February 28, 2012 said:

Yes would love to have a generic CAD file for editing - would like to try 10mm bore at one end to a metric acme rod...

phineasjw on February 28, 2012 said:

I added a .stp 3D CAD file exported from Alibre. I opened it in Inventor and it seems fine. Let me know if it works for you.

johnbentcope on February 27, 2012 said:

Very good man! Excellent part. I wish I still had the mill I could install this on...

Anonymous on February 27, 2012 said:

Precisely, my boy! 8-)

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License

Helical Cut Flex Coupling by phineasjw is licensed under the Attribution - Non-Commercial - Creative Commons license.

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