At only 4mm thick, this 6061 aluminum bashguard was the thinnest part I have attempted to machine!
I used a topology study in SolidWorks to generate a geometry suggestion for the part, given the load case it would be subjected to.
Result of the Topology Study
I determined this worst-case load case by assuming the rider lands the bashguard directly on a rock, with an additional torque load case of the rider smashing the bashguard head-on.
I learned about the various manufacturing controls such as thickness control and symmetry control while experimenting with this process!
Machining
Op 1 Complete
V2 vs V1
Soft Jaw #1
Soft Jaw #2
Soft Jaws Mounted
Clamped for Op 2
Final Face Pass before Chamfers
I still have a lot to learn about fixturing thin parts such as this one. In the future, I want to experiment with vacuum holding and superglue to achieve better surface finishes and minimize chatter during the second operation.
Image courtesy of Oak Components: Grown Bashguard 30T-34T ISCG 05 – OAK Components GmbH
As well as being the inspiration for this project, I would like to emulate the finish Oak Components can achieve on their bashguards as well as learn to anodize aluminum.
