2D valve handle

[jls667]

After our discussion the other day, I revised my valve handle. It was suggested to add a .035" diameter hole to make my straight lines easier to cut. I was given the impression that this change would lower the unit cost of my handle, but instead it raised the unit cost about 20%. Attached is the before and after design. Any suggestions on how I could lower the cost. For that price I could buy lots of extra plastic handles from the valve company.

John

[Tech2]

Please see Cost Reduction.

[jls667]

To save money I redesigned my valve handle in 2D. I am concerned whether this part is too thin to work a pool valve. Any suggestions or observations would be greatly appreciated.

[Tech2]

Thicker material would be stronger and consider stacking 2D parts. And remove the edge rounding.

[jls667]

I am not sure what you mean by stacking. Do you have an example Design I can see.

Would stacking two parts take the place of all my bending and weld the two parts together?

Assuming I leave all my bending, how do I know that my two holes will line up?

[Tech2]

Something like this. Bolt together. A little Locktite between the plates would make it even stronger.

[jls667]

Not only do I like your stacking example, I like the design too. Do you think a pop rivets would work instead of bolts?

[Tech2]

Yes rivets are probably even better if you have the capability or we could do it for you via Comments To Machinist.

[jls667]

Great. I have just a few more quick questions. It looks like I will be able to get a good valve handle at a reasonable price.

1. What does it cost to have you rivet my parts?

2. Do you use rivets made out of the same material as my part? This handle stays outside, so I need materials that will not rust.

3. What size hole should I use for rivets in my design?

4. Which type of Aluminum do you think is best for this handle? I would have liked a handle out of stainless steel, but that costs too much more. Will Aluminum be good for a handle that stays outiside 365 days a year?

5. In my note to the machinist, what do I need to specify?

[Tech2]

1. Please see Line | Machine | Comments To Machinist.

2. Your choice but probably a good idea in this case.

3. You need to make some of your own design decisions unless you want to use our design service.

4. Alum 5052. Yes.

5. Whatever is not clear from the drawing.

[jls667]

Let me clarify the main rivet question. I just wanted to know my choices of rivet diameters and materials. It would be nice to finalize my design.

[Tech2]

Please see Hardware Assembly.

[jls667]

I am getting two errors that I need help with before I place the order.

1. Auto Selected circle(s)/arc(s) are too small. If the problem is not visible, zoom in for a close view.
Consider enlarging radius to at least 0.045".

2. Auto The point(s) indicated by the dot may be too narrow at the selected line.
It is recommended to revise the design so that the narrow region is at least 0.099" wide or reduce the material thickness.

When I spoke to your machinist, he told me I needed a .035" diameter hole. The error mentions a .045" radius hole. Do I really need a hole that large?

I am not sure what to do about #2 error.

Thank you, John

[Tech2]

The software is being a bit conservative in this case. You can proceed to order. However you could resolve the errors by increasing the radius as advised and moving the center of the arcs out a bit so that you don't loose any depth of the teeth.