Overview:
SR25 Dog Clutch Housing and Linear Rail System
I designed and manufactured a lightweight and easily manufacturable shroud for the 4WD system dog clutch. I also designed a new system to constrain the throwout fork with a linear rail, allowing for smoother and more consistent engagement and disengagement of our 4WD system. This system allowed the system to cycle consistently for 500+ engagements at full engine torque without failure.
There were 2 major constraints to my design for this shroud:
- It needed to be at least 0.125 inches thick radially to comply with the rules about hazardous release of energy(HROE)
- Due to the amount of other CNC parts that needed to be produced, it would need to be a manually machined component
With these constraints in mind, I decided that the design would center around commonly available tube sizes cut to length, and waterjet-cut sheet aluminum. The constituent components would then be welded together to form the complete housing. This allowed for the final product to be relatively simple to weld together with a 3D printed fixture I designed.
