Slowmo shot of cutting a keyway on a CNC EDM. Definitely overkill, but easier than broaching the keyways on a taper for these sprockets:
These are for a remote control wheelbarrow project I’ll share later. For setup the sprocket was put in a v-block and tilted so the taper angle was vertical. The graphite electrode is just a long rectangle. This was done on a CNC EDM, not a sinker, so we went to full depth, burned in from the front, then burned into the corners to get to the final width.
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