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Old 08-30-12 | 06:22 AM
  #26  
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the_tool_man
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Joined: Jul 2008
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From: Spartanburg, SC, USA

Bikes: 1983 Fuji Touring Series IV, Masi Volumetrica 3VC

For those who propose drilling halfway through to reduce the liklihood of cracking, I wouldn't assume that without some analysis. It wouldn't surprise me at all if drilling a hole partway through created a higher stress concentration in the arm than if the hole passed completely through. This is especially true if you just use a drill bit or an end mill to make the hole. The sharp point or edge at the bottom of the hole would concern me. A ball end mill would be better. But again, if the diameter is too small, you can still create a stress concentration at the bottom.

If it were me, I'd model the thing in CAD and do some FEA analysis before I started making chips. Hmm....that might be fun (yeah, I know, I need to get out more).
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