I have a small POM bevel gear with these dimensions:
It has a 6mm hole for the shaft and a M4 hole for the set screw.
Suppose this bevel gear is meshed with a 45T bevel gear and give a max. output torque of 0.4kg/cm. How should the design of the 6mm shaft be? Should the diameter be precisely 6mm? Should it be flattened into a 'D' shape (so that the set screw can hold the shaft)? I'm planning to use a metal shaft.
Any help will be appreciated.