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I need to permanently attach these two 2 idler gears together. I had in my mind to drill a hole centered on the joint line & axially insert a key-like dowel pin (matching drill bit shank cutoff) parallel to the shaft. The axle hole is 5mm ID. The intersecting hub is 7.5mm OD x 4.5mm long. I'm actually not too keen about drilling because the remaining wall thickness gets skinny to the axle hole. The gears are steel, maybe something like 4140. Can someone provide the magic equations to determine shear strength for:
1) No pin, Loctite only on circular hub (specs say 4000 psi if that's the right number). Assume the rear face is not contributing anything because its mostly tooth form. So just the green hub area.
2) key-like axial steel pin as a function of diameter, say 1/32" just as initial guess. For example 1/16" diameter pin leaves only 0.018"
3) just for kicks, a perpendicular pin drilled through the valley of the big gear tooth into the hub (so the circular cross section of pin, maybe larger diameter).
1) No pin, Loctite only on circular hub (specs say 4000 psi if that's the right number). Assume the rear face is not contributing anything because its mostly tooth form. So just the green hub area.
2) key-like axial steel pin as a function of diameter, say 1/32" just as initial guess. For example 1/16" diameter pin leaves only 0.018"
3) just for kicks, a perpendicular pin drilled through the valley of the big gear tooth into the hub (so the circular cross section of pin, maybe larger diameter).
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