Author Topic: Planis Farm Boy Engine  (Read 6528 times)

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #15 on: June 08, 2020, 09:33:59 PM »
Thank you gentlemen for the kind comments!

Terry, actually I'm doing both. To mill aluminum I'm using a little bit of coolant mixed into the airstream mainly to provide some lubrication. Milling steel with the carbide cutter is done dry. For carbide it's better to use either a lot of coolant (really flood it) or none, because if there's only little coolant the thermal stress on the cutting edge is increased and the cutter won't last as long.
The air helps to keep the swarf away from the surface. This is also vital to mill steel with high feedrates because otherwise the cutter tends to gall up and break. With the aluminum it helps the finish if there ar no chips mangled between the cutter and the finished surface.

Plani

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #16 on: April 29, 2022, 08:52:57 PM »
Oh dear, how time flies by..... :old:

Nevertheless, some Progress was made but I didn't get around to keep the buildlog up to date. I'll try to catch up, since some Pictures were taken along the way.

Next up the Flywheels needed some finishing work. Therefore the split collets used to clamp the flywheels to the crankshaft where prepared by turning them whit some stock left on the outer diameter and the bore reamed.

Drilling and tapping the holes for the bolts




The flywheels where then set up in the lathe in order to turn the conical bore for the collet and the rim in the same setup






To ensure a proper fit of the collets, a mandrel was devised and the conical outer diameter was turned with the compound slide of the lathe still set at the same angle as for the bore in the flywheels, running the lathe backwards




Collet finished turning




Cutting the slits in the collets




In order to align the keyway to the spokes, a custom guide for the broach was made




Broach in action




Flywheels finished  :D



Plani




Offline propforward

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Re: Planis Farm Boy Engine
« Reply #17 on: April 29, 2022, 11:44:24 PM »
Excellent. Nice parts, and thanks for sharing your description of the process.
Stuart

Forging ahead regardless.

Offline crueby

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Re: Planis Farm Boy Engine
« Reply #18 on: April 30, 2022, 12:51:59 AM »
Those flywheels look terrific!

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #19 on: May 08, 2022, 07:39:10 PM »
Thank you gentlemen for the kind comments!

Next I wanted to start with the parts for the engine frame. I was able to purchase a decent chunk of aluminum to make these parts from.

Some work on the saw was needed




And some cutoffs were made on the mill




Raw parts for the water hopper, ant the two part engine frame prepared




Stay tuned, there's some machining ahead  ;) ;D ;D
Plani

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #20 on: May 11, 2022, 07:42:55 PM »
Hi everyone

Since there is quite some material on the bottom of the engine frame, I decided to place there an additional plate with four screws for each half of the frame in order to fix the parts of the frame.
This requires an additional pocket to be milled in the bottom of the frame, like so:




I started then with milling the front half of the frame.
Squaring up the stock.




Milling the front radius




Milling the pocket and reliefs for the fixing plate.




Pocket done and holes drilled and tapped.




Threads where the water hopper will be fixed and hole for the lubrication.




Then a pocket was milled where the cylinder will be fitted. The pocket is a bit deeper than the wall of the frame will be.




Next the radius on the upper side of the frame was milled.




Milling the top radius.




Holes for the bolts to connect the frame parts drilled and countersunk.




Milling the connecting part of the frame.




And then there is only a pretty deep pocket left to be done.




finishing cut with a ball nose endmill to create the radii in all corners.




Done  ;D  The thread for the oiler on top is missing, since I haven't decided on the size of the oiler yet.




Thank you for following along
Plani


Offline Roger B

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Re: Planis Farm Boy Engine
« Reply #21 on: May 11, 2022, 08:21:04 PM »
Looking good  :praise2:  :wine1:

What is the boring tool you are using to turn the taper in the flywheel? I am used to the boring bar being held in the tool post.
« Last Edit: May 12, 2022, 11:45:33 AM by Roger B »
Best regards

Roger

Offline Admiral_dk

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Re: Planis Farm Boy Engine
« Reply #22 on: May 12, 2022, 11:24:00 AM »
Very nice work converting stock to chips .... The parts looks fantastic  :praise2:

Per

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #23 on: May 12, 2022, 08:47:32 PM »

Thank you Roger and Per  :cheers:

Roger, to turn the taper I used a normal HSS boring bar. The only thing is, since the boring bar is rather small compared to the tool holder I used a clamping device to hold it and this device was then fixed in the tool holder.



Plani

Offline propforward

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Re: Planis Farm Boy Engine
« Reply #24 on: May 12, 2022, 09:07:25 PM »
This is great - lovely precision work that you are doing.
Stuart

Forging ahead regardless.

Offline Bearcar1

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Re: Planis Farm Boy Engine
« Reply #25 on: May 13, 2022, 10:35:31 PM »
Terrific piece of work! I appreciate your simple, no-nonsense approach in achieving the end results.  :cheers:


BC1
Jim

Offline Roger B

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Re: Planis Farm Boy Engine
« Reply #26 on: May 14, 2022, 07:32:28 AM »
Thank you  :) All is clear with a view from the other side.
Best regards

Roger

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #27 on: May 25, 2022, 09:41:27 PM »
Thank you gentlemen for the kind comments!  :cheers:

Next i made the fixing plate




as well as some bearing caps. The caps were then cut off the stock and milled flat on the bottom side




thank you for following along
Plani

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #28 on: May 27, 2022, 10:50:06 AM »
Hi everyone

The next substantial part for the engine is the rear part of the frame.
I started by squaring up the stock.




Then the step on the rear end of the engine was milled square at first, leaving some stock in the corner to mill the radius.




Milling the radius using a ball nose endmill.




Then the part was tilted over to mill the angled face, trying to hit the tangent of the radius  ;D




In the same set up the cutout for the big end is milled.




The cut out is a little deeper than the wall thickness will be.




Roughing out the pillow block. The pocket for the fixing plate in the bottom was milled before.




Finishing the pillow block with an end mill with a radius.




Same thing on the other side.




Some more stock is left for the camshaft.




2nd side finished the radius on top was milled using a radius cutter.




Starting the deep pocket on the inside.




The pocket ist milled vertical first, also leaving some stock for the corner radii.




For the finishing cuts the head of the mill was tilted over to reach all the way in the corner.




Taking light cuts, I got away without chatter.




Test fit  ;D




Then the upper halves of the bearing blocks were installed and the bores for the bearings milled.






Family shot.




Thank you for following along.
Plani


Online Kim

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Re: Planis Farm Boy Engine
« Reply #29 on: May 27, 2022, 05:05:48 PM »
Wow!  That's some really nice work to reduce that block down to a part.  Amazing work!
Are you using CNC for this? 
Kim

 

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