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Do the ends of the slots need to have the same radius as the sides? If not, grinding would be the way to go.
not necessarily, they're breathing ports past a gland
In that case, it would be kind of you to keep the radius shallow (i.e. not perpendicular to the rod) at the ends. Your seal will be much more comfortable with such an arrangement if it's dynamic.
That's a good point, the less it moves the less likely to embrittle and fail.
If the gland must seal on the unscalloped part then I'd rethink that profile to remove any sharp edges. Any edge that touches the gland should be radiused and polished. If not, the MTBF will be measure is single or double digits of cycles I think, depending on gland design.
As a wild ass idea, you could drill several radial holes, with radiused and polished edges, where the scallops end on the current design. Then drill a small axial hole down the center of the shaft, and add a seal plug. If you make the gland surface bigger (longer along the shaft axis) than the holes, you might get better life. The center of the shaft doesn't do much, so drilling axially shouldn't weaken it much.
Considering doing an electro control system with a solenoid triggering off crank timing, this is complex and is likely going to cause issues later with the seal.
It's for a personal project, but I need to cut these into a pretty hard hydraulic cylinder shaft. What's the best way of doing so? Cungsten Tarblide, obviously, but any special flavors?
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