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Tegheim 08-30-2011 03:34 PM

1 Attachment(s)
Well, the year goes againt darker times here in Sweden. Luckily that means more time inside the garage, workshop and with the computer.

Last week I got Solidworks 2011, and startet tonight to practice. It's not much, but I'm satisfied with the result.



Attachment 16289



The CAD shows my 184mm Tilton clutch. Soon, there will be blo... cnc-porn? https://www.nopistons.com/forums/pub...IR#>/smile.png

Regards Tegheim

Tegheim 08-31-2011 12:10 PM

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The assembly is done!

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Baldy 09-02-2011 12:14 PM

Nice! I just saw an episode of the show "How It's Made", and they showed high-performance race clutches being CNC'd and assembled, high quality craftsmanship goes into that!

Tegheim 09-03-2011 05:22 AM

Could you get that episode's name so I can download it? :P

Tegheim 09-05-2011 12:53 PM

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Its getting there...



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Baldy 09-06-2011 08:46 AM


Originally Posted by Tegheim (Post 849955)
Could you get that episode's name so I can download it? :P

I didn't view this link (blocked at work), but I think this is it: www.youtube.com/watch?v=LJ-0gTqWMYA

Tegheim 09-07-2011 01:46 PM

1 Attachment(s)
Another night in SolidWorks...

Attachment 16274

Tegheim 09-09-2011 07:45 AM

http://www.youtube.com/watch?v=y-K-bPovT2M

Tegheim 09-12-2011 10:17 AM

http://www.youtube.com/watch?v=RWUreTHxOE0

Tegheim 09-23-2011 11:28 AM

1 Attachment(s)
Have made my own tool for the little jack into the loosen shaft-parts. Don't know the english word for it.

3.40mm wide and 5.70mm deep. Then put an insert for a lathe there, tada! https://www.nopistons.com/forums/pub...IR#>/smile.png



https://i815.photobucket.com/albums/...d/IMAG0644.jpg

Attachment 16266

Tegheim 09-24-2011 04:02 AM

I have now google-translated to explain myself https://www.nopistons.com/forums/pub...IR#>/smile.png



This tool I will put into my CNC-mill. Lock the spindel still. Then I will "shave" of the material inside the lose shaft-parts to make the KEYWAY https://www.nopistons.com/forums/pub...IR#>/smile.png

Yesterday the word "keyway" wasn't in my head, soo I used the word jack https://www.nopistons.com/forums/pub...DIR#>/wink.png

Tegheim 09-25-2011 03:34 AM

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This picture maybe help you all understand what I'm about to try out.

This is an 20B-front just for show.

I will now make an fixture to hold the same of mine, the with the spindle off, cut about 0.1mm at time i stages untill i got the right keyway.

Attachment 16264

Tegheim 09-25-2011 05:11 AM

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First attempt!

Have done a keyway in a test-piece. Works fine! And now I will continue with the fixture for the real deal...

Movie on the way!





Attachment 16263

Tegheim 09-25-2011 05:30 AM

http://www.youtube.com/watch?v=RDZqUQ_jJn8

morotor 09-29-2011 12:03 PM

Great stuff, from the sounds of it and i get the videos but no pictures. Can anyone help me with that?

morotor 09-29-2011 12:13 PM

Tegheim.. are you using CAM software to import your 3D models into programming language for the machining centers or are you writing the G-code for all the CNC work? I figure you are just following factory spec. for this project, have you thought about making any modifications eventually.. having the models and given the analysis packages available for solidworks you could play with material, weight, etc.

Tegheim 10-01-2011 03:54 AM

6 Attachment(s)
Time for a little update!

Sadly my HTC Desire isn't the best camera in workshop-lights...

Have finally got along with the Keyway!

First, I did new irons to the vise (correct name? Google translate)

They are mounted from the inside with M10-bolts

Attachment 16257



A hole at 43.61mm, and an Radius 6.0mm to give clearance for Radius 5.0mm on the eccentric.

This is not bored, so the surface is just roughed yet.

Attachment 16258



Exact precision!

Attachment 16259



Like a glove! https://www.nopistons.com/forums/pub...IR#>/smile.png

https://i815.photobucket.com/albums/...d/IMAG0683.jpg



Indication of a cam, I have my zero point where I did the fixture, so then you have easy track of the eccentric theory should lie on the X 15.0mm Y0.0mm.

Attachment 16260



A final inspection of the tool. Indicates the track of the tool in the X-axis, thus I know that it is angled precisely 90grd.

Using the M-code M19 in the machine, so I lock the spindle in the same place every time.

Attachment 16261



This is what working out, it will actually go much faster, when the cutting speed in such a cut is about 80-120m/min, ie as soon as it will go through the material. Easy as it spins to get the cutting speed, but now the cut stands still. So I drive 2m/min:) or F2000.0 as many may know. Takes just 0.1mm per insert to avoid accidents in my fine pieces https://www.nopistons.com/forums/pub...IR#>/smile.png

[media]http://www.youtube.com/watch?v=wqGoEAxAFRQ[/media]





Results! Keyway on 5.00-5.01mm width, and depth with little clearance.

https://i815.photobucket.com/albums/...d/IMAG0693.jpg

Attachment 16262

John Huijben 10-02-2011 11:26 AM

Looks good!

I wish I had that sort of equipment at my disposal, I'm attempting something similar with conventional machines, lots and lots of work.

What sort of heat treatment did the shaft get? Looking at the pictures it looks like the shaft was hardened and annealed.

How much room did you leave for grinding, about 0,5mm's?

Tegheim 10-02-2011 11:41 PM

The heat-treatment was normalization to kill the material again. The hardening comes after grinding.

I left about 0.5-0.6mm on the diameter for grinding.

John Huijben 10-04-2011 06:20 AM

That's interesting, I thought grinding should be done last, because the hardening will disort the material.

Tegheim 10-06-2011 11:56 PM

1 Attachment(s)
SolidWorks is an hard program to learn...

Attachment 16254

Tegheim 10-07-2011 12:18 PM

5 Attachment(s)
Tonight I made a little keyway in the crank, which corresponds to the ones I did in the eccentric.

A male cutter, one must have ...

Attachment 16249

Important to buckle without moving it!

Attachment 16250

Finished setup.

Attachment 16251

work work

Attachment 16252

That did it! The track is 5.01 mm wide and 43.5 mm long.

Easy to forget compensation for the shaft shall be grinded then when you set the depth.

Attachment 16253

Tegheim 10-08-2011 06:47 AM

This forum is very lonely https://www.nopistons.com/forums/pub...IR#>/smile.png



http://i815.photobucket.com/albums/z...d/IMAG0737.jpg

John Huijben 10-09-2011 11:57 AM

looks good,

the cad model in solidworks doesn't look right by the way. I have a pretty accurate model of a rotor housing in solidworks, PM me if you need it.

Tegheim 10-19-2011 01:28 PM

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shainiac 10-19-2011 08:00 PM

Looks awesome! Keep up the great work!

Tegheim 10-20-2011 01:15 PM

1 Attachment(s)
Just for fun... https://www.nopistons.com/forums/pub...IR#>/smile.png

https://i815.photobucket.com/albums/...d/IMAG0801.jpg

Attachment 16240

John Huijben 10-20-2011 01:43 PM

It's a shame you can't see it when the engine is together. Someone needs to figure out how to make rotor housings and iron's made out of glass or something https://www.nopistons.com/forums/pub...DIR#>/cool.png

Tegheim 10-20-2011 02:09 PM

Maybe WE could be this "someone"?

You have the energy, knowledge of CAD https://www.nopistons.com/forums/pub...IR#>/smile.png

John Huijben 10-21-2011 03:21 PM

Yes, but I don't have the awasome cnc machining equipment.

Joking aside, I've heard from a buddy of mine that studies automotive engineering that they had a working 4stroke test engine that had a transparant head and cylinder. I don't know what kind of materials they used but apparantly they injected a coloured dye in the intake channel and recorded video footage in super slowmotion, so they could actually see what's going inside the engine.

Pretty cool but, like a lot of cool things, not for the hobbyist.

mazdaspeed7 10-21-2011 05:13 PM

Ive heard of crystal(sapphire maybe) viewing ports in the head of test engines, but never a full head or cylinder

Tegheim 10-27-2011 02:32 PM

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Today I made a decision... and ordered some material... https://www.nopistons.com/forums/pub...1047683664.gif

http://i815.photobucket.com/albums/z...d/IMAG0824.jpg

Attachment 16238

typical me... https://www.nopistons.com/forums/pub...R#>/tongue.png

Baldy 10-28-2011 01:58 PM

This is amazing.

Tegheim 11-02-2011 02:27 PM

1 Attachment(s)
Got an big piece yesterday...





Attachment 16236

Tegheim 11-04-2011 11:50 AM

Today the E-shaft was left to it first grinding-session. Feels strange https://www.nopistons.com/forums/pub...IR#>/smile.png

I should add that I am not entirely alone in this with billet rotors.

My friend Gustav and I often get yelled at for talking more with each other, then our partner's when we are sitting with headsets and drawing SolidWorks at night:)

We have our visions. I want my 4rotor, and Gustav wants his "tired" 770hk 13B will go a bit better:)



http://i815.photobucket.com/albums/z...ild/gavlar.jpg

jwteknix 11-04-2011 09:24 PM

are u and john sharing info on ur builds? what are the differences in the motors?

Tegheim 11-05-2011 06:12 AM


Originally Posted by jwteknix (Post 850780)
are u and john sharing info on ur builds? what are the differences in the motors?



Now lately we talk little about our builds. But no one of us had copied the other.

We have both drawned and design our own E-shaft.

I think John is a little more "builder" than me, he uses no CNC-machines https://www.nopistons.com/forums/pub...IR#>/smile.png

John Huijben 11-05-2011 11:36 AM

Nope I don't, I wish I could, but I don't have acces to them. https://www.nopistons.com/forums/pub..._DIR#>/sad.png

I'm also not taking things as far as you have, I'm just fabricating the most basic parts needed to run a 4-rotor, so no billet rotors or anything.



Nice pieces of round material, is that the same type of material that you used for the e-shaft?

I still think you should've gone with aluminium though, yeah the seal grooves will wear more quickly but engine response will be insane. https://www.nopistons.com/forums/pub...IR#>/smile.png

Maybe a DLC coating (www.kexel.de) or a TiN coating.

Tegheim 11-05-2011 03:55 PM

But with awsome response, the driving trough town will be harder https://www.nopistons.com/forums/pub...IR#>/smile.png

At first we try iron-rotors with less then 4000grams. Then we go futher.

Tegheim 11-06-2011 11:59 AM

3 Attachment(s)
Added the primary-port. If you don't want to PP...

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