wheel-rotor.kcl

// Wheel rotor
// A component of a disc brake system. It provides a surface for brake pads to press against, generating the friction needed to slow or stop the vehicle.


// Define constants
// Base units for this model are in inches
rotorDiameter = 12
rotorInnerDiameter = 6
rotorSinglePlateThickness = 0.25
rotorInnerDiameterThickness = 0.5
lugHolePatternDia = 3
lugSpacing = 114.3 * mm()
rotorTotalThickness = 1
spacerPatternDiameter = 11
spacerDiameter = 0.25
spacerLength = rotorTotalThickness - (2 * rotorSinglePlateThickness)
spacerCount = 16
wheelDiameter = 19
lugCount = 5
yAxisOffset = 0.5
drillAndSlotCount = 5

rotorPlane = {
  plane = {
    origin = { x = 0, y = yAxisOffset, z = 0 },
    xAxis = { x = -1, y = 0, z = 0 },
    yAxis = { x = 0, y = 0, z = 1 },
    zAxis = { x = 0, y = 1, z = 0 }
  }
}

fn lugPattern(plane) {
  lugHolePattern = circle({
         center = [-lugSpacing / 2, 0],
         radius = 0.315
       }, plane)
    |> patternCircular2d({
         arcDegrees = 360,
         center = [0, 0],
         instances = lugCount,
         rotateDuplicates = true
       }, %)
  return lugHolePattern
}

rotorSketch = startSketchOn(rotorPlane)
  |> circle({
       center = [0, 0],
       radius = rotorDiameter / 2
     }, %)
  |> hole(lugPattern(%), %)
rotor = extrude(rotorSinglePlateThickness, rotorSketch)

rotorBumpSketch = startSketchOn(rotorPlane)
  |> circle({
       center = [0, 0],
       radius = rotorInnerDiameter / 2
     }, %)
  |> hole(lugPattern(%), %)
rotorBump = extrude(-rotorInnerDiameterThickness, rotorBumpSketch)

rotorSecondaryPlatePlane = {
  plane = {
    origin = {
      x = 0,
      y = yAxisOffset + rotorTotalThickness * 0.75,
      z = 0
    },
    xAxis = { x = -1, y = 0, z = 0 },
    yAxis = { x = 0, y = 0, z = 1 },
    zAxis = { x = 0, y = 1, z = 0 }
  }
}

secondaryRotorSketch = startSketchOn(rotorSecondaryPlatePlane)
  |> circle({
       center = [0, 0],
       radius = rotorDiameter / 2
     }, %)
  |> hole(lugPattern(%), %)

secondRotor = extrude(rotorSinglePlateThickness, secondaryRotorSketch)

spacerSketch = startSketchOn(rotorSecondaryPlatePlane)
  |> circle({
       center = [spacerPatternDiameter / 2, 0],
       radius = spacerDiameter
     }, %)
  |> patternCircular2d({
       arcDegrees = 360,
       center = [0, 0],
       instances = spacerCount,
       rotateDuplicates = true
     }, %)

spacers = extrude(-spacerLength, spacerSketch)

rotorSlottedSketch = startSketchOn(rotor, 'START')
  |> startProfileAt([2.17, 2.56], %)
  |> xLine(0.12, %)
  |> yLine(2.56, %)
  |> xLine(-0.12, %)
  |> lineTo([profileStartX(%), profileStartY(%)], %)
  |> close(%)
  |> patternCircular2d({
       center = [0, 0],
       instances = drillAndSlotCount,
       arcDegrees = 360,
       rotateDuplicates = true
     }, %)

rotorSlotted = extrude(-rotorSinglePlateThickness / 2, rotorSlottedSketch)

rotorDrilledSketch = startSketchOn(rotor, 'START')
  |> circle({ center = [1.34, 3.23], radius = 0.12 }, %)
  |> patternLinear2d({
       axis = [-0.02, 0.04],
       instances = 3,
       distance = 1.1
     }, %)
  |> patternCircular2d({
       center = [0, 0],
       instances = drillAndSlotCount,
       arcDegrees = 360,
       rotateDuplicates = true
     }, %)

rotorDrilled = extrude(-rotorSinglePlateThickness, rotorDrilledSketch)

secondRotorSlottedSketch = startSketchOn(secondRotor, 'END')
  |> startProfileAt([-2.17, 2.56], %)
  |> xLine(-0.12, %)
  |> yLine(2.56, %)
  |> xLine(0.12, %)
  |> lineTo([profileStartX(%), profileStartY(%)], %)
  |> close(%)
  |> patternCircular2d({
       center = [0, 0],
       instances = drillAndSlotCount,
       arcDegrees = 360,
       rotateDuplicates = true
     }, %)

secondRotorSlotted = extrude(-rotorSinglePlateThickness / 2, secondRotorSlottedSketch)

secondRotorDrilledSketch = startSketchOn(secondRotor, 'START')
  |> circle({ center = [1.34, 3.23], radius = 0.12 }, %)
  |> patternLinear2d({
       axis = [-0.02, 0.04],
       instances = 3,
       distance = 1.1
     }, %)
  |> patternCircular2d({
       center = [0, 0],
       instances = drillAndSlotCount,
       arcDegrees = 360,
       rotateDuplicates = true
     }, %)

secondRotorDrilled = extrude(-rotorSinglePlateThickness, secondRotorDrilledSketch)