Created a slotted lever

[raydeleu]

This slotted lever was created using the design from Solidworks Model Mania, https://blogs.solidworks.com/tech/wp-content/uploads/sites/4/Model-Mania-2008-Phase-1.jpg.

I used an intersection of drawings to create the circular slot. The slot is based on an intersection between to circles and a circle-segment. The keyway for the main axle, called axleHoleShape is created by fusing two drawings. The shape is missing some fillets as OpenCascade was not able to create these without error. The code still contains two lines for fillets. By uncommenting one of the lines you can check the result, adding both fillets at the same time results in a kernel error.

const { draw, drawCircle, drawRectangle} = replicad;

const main = () => {

// dimensions of slotted lever
let axleHoleRadius = 22/2;
let axleRadius = 35/2;
let keySlotHeight = 6;
let keySlotWidth  = 2.50;  
let axleWidth = 30;
let dist = 100;
let slotOuterRadius = 12
let slotAngle = 30/180*Math.PI
let dh = axleRadius - slotOuterRadius
let minAngle = Math.asin(-dh/dist);
let maxAngle = minAngle + slotAngle;
let startPoint = [Math.cos(minAngle)*(dist+slotOuterRadius),Math.sin(minAngle)*(dist+slotOuterRadius)]
let endPoint = [Math.cos(maxAngle)*(dist+slotOuterRadius),Math.sin(maxAngle)*(dist+slotOuterRadius)]
let startPointCircle = [Math.cos(minAngle)*(dist),Math.sin(minAngle)*(dist)]
let endPointCircle = [Math.cos(maxAngle)*(dist),Math.sin(maxAngle)*(dist)]

let axle = drawCircle(axleRadius)
.sketchOnPlane("XZ").extrude(axleWidth);

let plate = draw()
.movePointerTo([0,-axleRadius+6])
.lineTo([0,-axleRadius])
.lineTo([100,-axleRadius])
.lineTo([90,-axleRadius+6])
.lineTo([38,-axleRadius+6])
.tangentArc(-5,30)
.tangentArc(50,28)
.polarLineTo([100,33.5])
.ellipseTo([0,axleRadius],175,175)
.lineTo([0,axleRadius-6])
.ellipseTo([0,-axleRadius+6],11,11)
.close().sketchOnPlane("XZ",3).extrude(14)

let slotOuter = drawCircle(dist+slotOuterRadius)
let slotInner = drawCircle(dist-slotOuterRadius)
let segment = draw().lineTo(startPoint).line(0,50).lineTo(endPoint).close()
let slotRing = slotOuter.cut(slotInner)  
let slotSegment = slotRing.intersect(segment)
let slotRoundStart = drawCircle(slotOuterRadius).translate(startPointCircle)
let slotRoundEnd = drawCircle(slotOuterRadius).translate(endPointCircle)
slotSegment = slotSegment.fuse(slotRoundStart)
slotSegment = slotSegment.fuse(slotRoundEnd)
let slotSegmentInner = slotSegment.offset(-6)
let slotSegmentOuter = slotSegment.cut(slotSegmentInner).sketchOnPlane("XZ",2).extrude(16)

let axleHole = drawCircle(axleHoleRadius)
let keySlot  = drawRectangle(2*keySlotWidth,keySlotHeight)
.translate(-axleHoleRadius,0)
let axleHoleShape = axleHole.fuse(keySlot).sketchOnPlane("XZ",-10)
let axleCutter = axleHoleShape.extrude(30+20)
axle = axle.cut(axleCutter)

axle = axle.fuse(slotSegmentOuter)
axle = axle.fuse(plate).fillet(0.8,(e)=>e.inPlane("XZ",2))
axle = axle.fillet(0.8,(e)=>e.inPlane("XZ",2+16))
//axle = axle.fillet(1,e=>e.containsPoint([0,-17,17.5]))
//axle = axle.fillet(1,e=>e.containsPoint([0,3,17.5]))

return [
//{shape: axleCutter, color: "silver", opacity: 0.6},
{shape: axle, color: "steelblue"}
];
};

[raydeleu]

Here is the slotted lever with fillets. The shape was exported from Replicad and then imported in OnShape. The missing fillets were added in OnShape. Some of the fillets failed in OnShape as well, illustrating the difficulty of creating fillets in this shape.