TheSneeze wrote on 02/04/22 at 19:51:01:I am all ears on how you would measure the force being applied that way. Mechanically I understand where you are coming from, completely. From a practical set up stand point, how? Do you mean two vice jaws (one vice)? What instrument(s) would you use to measure the applied force? The failure mode of the part is the corners of the flats on the shaft are applying outward force on the double D hole, trying to push it apart from the inside. The rotation of the shaft in the double D hole. This is the force I was trying to duplicate. Not by rotating the shaft, but by rotating the part. Since I am not willing to go out and purchase any special fixtures or measuring tools for this, using a torque wrench (which I have) will need to suffice. I could cut the shaft short enough to still put the socket over the shaft and pawl. But testing that way would eliminate any allowable twist by the length of the shaft. Leaving the shaft full length and pinching the flats of the shaft in a vice eliminates my only method of measuring the force applied, unfortunately.
I'll try to set something up later today to show what I mean.
Your test applies a torque to the pawl, but this only tests the interface load between the shaft and pawl but lacks the shear load applied by the throw out rod itself.
Putting the shaft in 2 separate vices for support and clamping hard on the shaft lessons the load on the shaft by putting it into a double shear configuration which is a optimum.
Applying a downward load on the pawl at the throw out rod dimple fully replicates the application. The one thing I've learned in my many years of product development is test as it is used or you'll be surprised when it fails.
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