/** * chuck_mechanism.scad — TM-CWND-001 Rev A * Adjustable Chuck for Coil Winder Spindle * * Three modules (print separately): * 1. chuck_body() — outer ring + jaw tracks, mounts to spindle * 2. chuck_jaw() — print 3×, adjustable, M5 grub screw clamp * 3. chuck_backplate()— secures to spindle shaft, flanged * * Range: 6.35mm (1/4") to 102mm (4") coil former diameter * * Design: sliding T-slot jaw, not scroll chuck (simpler 3D print) * Jaw extension: 0 (fully retracted) to 40mm (fully extended) * At zero extension: grips 6mm forms (using center bore rubber insert) * At max extension: grips 102mm forms (jaws at outer track limit) * * Print settings: * Material: PETG (toughness, dimensional stability) * Infill: 80% for chuck body, 100% for jaws * Wall: 4 perimeters * Layer: 0.15mm (jaw track accuracy) * * Print envelope: * chuck_body: 160mm × 160mm × 35mm — fits in 200mm cube * chuck_jaw: 60mm × 25mm × 20mm — print 3 at once * backplate: 80mm × 80mm × 20mm */ // ─── Parameters ─────────────────────────────────────────────────────────────── chuck_od = 150.0; // Outer diameter of chuck body chuck_h = 32.0; // Total height chuck_id_bore = 20.0; // Center through-bore (spindle shaft pass-through) // Jaw T-slot track geometry jaw_count = 3; jaw_track_w = 14.0; // T-slot width at base jaw_track_h = 10.0; // T-slot depth jaw_track_len = 50.0; // Radial travel length jaw_t_w = 18.0; // T-slot cap width (wider than base) jaw_t_h = 5.0; // T-slot cap height jaw_start_r = 10.0; // Track center radius at minimum position (jaw retracted) // Jaw body jaw_body_w = 12.0; // Jaw body width (fits in T-slot) jaw_body_h = jaw_track_h - 0.4; // Height (sliding fit) jaw_body_l = 55.0; // Jaw body length (extends inward + outward) jaw_grip_w = 20.0; // Jaw face width (contacts former) jaw_grip_h = 20.0; // Jaw face height jaw_grip_step = 5.0; // Step from jaw body to grip face jaw_grip_groove = 2.0; // Grip groove depth (texture) jaw_setscrew_dia = 5.0; // M5 set screw through jaw body // Backplate bp_od = 80.0; bp_h = 18.0; bp_bore = 14.2; // 14mm shaft + clearance bp_bolt_sp = 60.0; // Bolt pattern (4× M4 to chuck body) bp_key_w = 4.0; // Key flat width bp_key_d = 2.0; // Key flat depth // Chuck-to-backplate bolt pattern c2bp_bolt_sp = 70.0; c2bp_bolt_dia = 4.3; // M4 clearance // ─── Chuck Body ─────────────────────────────────────────────────────────────── module jaw_track_slot(angle) { // Single T-slot track at given angle rotate([0,0,angle]) translate([chuck_od/2 - jaw_track_len - jaw_start_r, 0, 0]) rotate([0,90,0]) { // T-slot cross-section extruded radially linear_extrude(jaw_track_len + chuck_od/2) polygon([ [-jaw_t_w/2, 0], [-jaw_t_w/2, jaw_t_h], [-jaw_track_w/2, jaw_t_h], [-jaw_track_w/2, jaw_track_h], [ jaw_track_w/2, jaw_track_h], [ jaw_track_w/2, jaw_t_h], [ jaw_t_w/2, jaw_t_h], [ jaw_t_w/2, 0], ]); } } module chuck_body() { difference() { // Outer cylinder cylinder(h=chuck_h, d=chuck_od, $fn=128); // Center bore translate([0,0,-0.5]) cylinder(h=chuck_h+1, d=chuck_id_bore, $fn=32); // Three jaw tracks at 120° intervals for (a=[0, 120, 240]) translate([0, 0, chuck_h - jaw_track_h - 2]) jaw_track_slot(a); // Chuck-to-backplate bolts (from front face) for (a=[60, 180, 300]) rotate([0,0,a]) translate([c2bp_bolt_sp/2, 0, -0.5]) cylinder(h=chuck_h+1, d=c2bp_bolt_dia, $fn=16); // Weight relief pockets (back face) for (a=[0, 60, 120, 180, 240, 300]) rotate([0,0,a]) translate([chuck_od/2 - 20, 0, 0]) rotate([90,0,0]) cylinder(h=8, r=12, $fn=32, center=true); // Front face label recess translate([0,0,chuck_h-1.5]) cylinder(h=2, d=30, $fn=64); } } // ─── Chuck Jaw ──────────────────────────────────────────────────────────────── module chuck_jaw() { difference() { union() { // T-slider body (fits in chuck T-slot) translate([0, -jaw_body_w/2, 0]) cube([jaw_body_l - jaw_grip_step, jaw_body_w, jaw_body_h]); // T-cap (wider, engages T-slot) translate([0, -jaw_t_w/2 + 0.2, 0]) cube([jaw_body_l - jaw_grip_step - 5, jaw_t_w - 0.4, jaw_t_h - 0.2]); // Grip face (extends inward toward chuck center) translate([jaw_body_l - jaw_grip_step, -jaw_grip_w/2, 0]) cube([jaw_grip_step, jaw_grip_w, jaw_grip_h]); } // M5 clamp set screw (from side, locks jaw in track) translate([jaw_body_l/2, -jaw_body_w/2 - 1, jaw_body_h/2]) rotate([-90,0,0]) cylinder(h=jaw_body_w+2, d=jaw_setscrew_dia, $fn=16); // Grip face grooves (horizontal, texture for grip) for (z=[3, 8, 13]) translate([jaw_body_l - jaw_grip_step - 0.5, -jaw_grip_w/2 - 0.5, z]) cube([jaw_grip_step + 1, jaw_grip_w + 1, jaw_grip_groove]); } } // ─── Backplate ──────────────────────────────────────────────────────────────── module chuck_backplate() { // Mounts to spindle shaft, chuck body bolts to front face difference() { union() { cylinder(h=bp_h, d=bp_od, $fn=64); // Spindle shaft collar (extends behind main disc) cylinder(h=bp_h + 15, d=30, $fn=32); } // Shaft bore translate([0,0,-0.5]) cylinder(h=bp_h+16, d=bp_bore, $fn=32); // Key flat (D-flat on shaft) translate([bp_bore/2 - bp_key_d, -bp_bore, -0.5]) cube([bp_key_d+1, bp_bore*2, bp_h+16]); // Shaft set screw (M5 from side) translate([30/2+1, 0, bp_h+7]) rotate([0,-90,0]) cylinder(h=30, d=5.0, $fn=16); // Chuck bolt through holes for (a=[60,180,300]) rotate([0,0,a]) translate([c2bp_bolt_sp/2, 0, -0.5]) cylinder(h=bp_h+1, d=c2bp_bolt_dia, $fn=16); // Weight relief for (a=[0,90,180,270]) rotate([0,0,a]) translate([bp_od/2-12, 0, bp_h/2]) rotate([90,0,0]) cylinder(h=8, r=7, $fn=16, center=true); } } // ─── Small Form Insert (rubber sleeve for <25mm forms) ──────────────────────── module small_form_insert() { // Press-fit rubber or foam insert for gripping small coil formers // Design: cylindrical, tapered ID insert_od = chuck_id_bore - 0.4; insert_id_top = 6.0; insert_id_bot = 20.0; insert_h = 25.0; difference() { cylinder(h=insert_h, d=insert_od, $fn=32); cylinder(h=insert_h+1, d1=insert_id_bot, d2=insert_id_top, $fn=32); } } // ─── Render ─────────────────────────────────────────────────────────────────── $fn = 64; print_part = "body"; // "body" | "jaw" | "backplate" | "insert" | "all" if (print_part == "body") { color("lightgray") chuck_body(); } else if (print_part == "jaw") { // Print 3 at once for (i=[0:2]) translate([i*65, 0, 0]) color("orange") chuck_jaw(); } else if (print_part == "backplate") { color("lightblue") chuck_backplate(); } else if (print_part == "insert") { color("gray", 0.5) small_form_insert(); } else { // Assembly view color("lightgray", 0.8) chuck_body(); color("lightblue", 0.8) translate([0, 0, -bp_h]) chuck_backplate(); for (a=[0, 120, 240]) rotate([0,0,a]) translate([chuck_od/2 - jaw_track_len/2 - jaw_start_r, 0, chuck_h - jaw_track_h - 2]) color("orange") chuck_jaw(); } // ─── Notes ──────────────────────────────────────────────────────────────────── // ASSEMBLY: // 1. Press backplate onto spindle shaft (key flat aligned), tighten M5 set screw // 2. Insert jaws into T-slots from outer edge, slide inward until finger-tight // 3. Tighten jaw M5 grub screws to lock at current position // 4. For coil formers < 25mm OD: insert small_form_insert into center bore // and pinch former in place // 5. For formers 25–102mm: extend jaws to contact, tighten grub screws // // BALANCE: Heavy-gauge wire wound at high RPM may unbalance the chuck. // Maximum safe RPM with chuck: ~150 RPM (limited by bearing vibration) // For >100 RPM: use lighter chuck or dynamically balance jaws.