IHC Titan 50 HP, 2 cylinder Doug Kelley, European version

[Admiral_dk]

Seht gut aus Achim - looks great Achim 

I guess that the top and the M3 screws will be milled too 

I simply couldn't remember you making the cylinders .... and them I looked again and can see that they are 3D printed 

Per

[Craig DeShong]

This engine reminds me of the ‘90 Hp three ball Kline’ up at the Rough and Tumble Engineers Assoc. in Kinzers Pa.  Lots of similarities.  This looks like a great project, I was thinking of building the Klein at one time myself, might just get back to it with this encouragement.

[fumopuc]

This engine reminds me of the ‘90 Hp three ball Kline’ up at the Rough and Tumble Engineers Assoc. in Kinzers Pa.  Lots of similarities.  This looks like a great project, I was thinking of building the Klein at one time myself, might just get back to it with this encouragement.

Hi Craig, is it this engine you are taking about ?
<a href="https://www.youtube.com/watch?v=MpmU9rW-FD0" target="_blank">http://www.youtube.com/watch?v=MpmU9rW-FD0</a>
Very impressive this very slow movement of all these levers,
It reminds of some Corliss engines.

[Craig DeShong]

Yes Achim, I didn’t realize there was a video of it running.  Lots of interesting motion to model.  Thanks for looking it up and showing.

[fumopuc]

Seht gut aus Achim - looks great Achim 

I guess that the top and the M3 screws will be milled too 

I simply couldn't remember you making the cylinders .... and them I looked again and can see that they are 3D printed 

Per

Per thanks.
The cylinder unit was my very first sample part, 3D printed end of spring time last year.
Reason was to get a better idea about the different possibilities for set up at the machines.
I.E. at the lathe, mostly done for a member of our German forum here, who was worried it could not fit to his lathe if he will ever start a build by his own.
For me it is a good sample now for any kind of sample assembly.

[fumopuc]

Drilling and thread milling the next operations at the base.
I do like these tiny thread milling cutter a lot now.
But still I can´t watch the tool diving into the hole first time.
My health condition there is close to a heart attack still every time I do use it.
I press the start button to run the CNC program after the tool change to the thread cutter but looking out of the window than.

[Craig DeShong]

But still I can´t watch the tool diving into the hole first time.
My health condition there is close to a heart attack still every time I do use it.
I press the start button to run the CNC program after the tool change to the thread cutter but looking out of the window than.

I’m laughing and commiserating with you at the same time.  I think we’ve all been there.

[Roger B]

I wonder if it would be possible to make a working (maybe for a short time  ) IC engine with 3D printing 

[fumopuc]

I wonder if it would be possible to make a working (maybe for a short time  ) IC engine with 3D printing 

Hi Roger, there are some videos at YT.
One engine is made by LEGO.
This guy  was close with his 3D printed engine.
He is using a 3D printed cylinder head at a lawn mover.
I am sure there will be more all over the world.

[fumopuc]

Next action with the base build.
As mentioned earlier it is bit banana like shape.
But nothing what not can been hidden easily.
First I have marked the position of the holes  best guess by visual judgment.
For general orientation it was checked against a print.
There is a a dent in one side wall still.
But I will leave it as it is. That will the special note of this build.
In Fusion CAM the little plates for increasing the holes are prepared.
They will all machined in one set up.

[Kim]

You're making some great progress on your engine, Achim!

And those videos you posted are pretty interesting. I wondered how the Lego engine would do and it was just about what I thought - they all melted - But it was an interesting experiment!  The printed engine was interesting as was the lawnmower head experiments.  Thanks for sharing them!

Kim

[fumopuc]

Hi Kim, thanks. This printed engine could be a real fun project.




Next to do, milling of the little straps.
To get them fixed with soft soldering and to get rid of the temporary bolting.

[fumopuc]

Last part of making the base.
Finishing only.

[fumopuc]

Hi everybody, next to do, the parts for the silver brazed crank case.
Also here I have tried to do it with my newly self made vacuum table, but with medium success only.
I would say  that I have hit the limit of surface which could be kept down with my table configuration.
The flat surface and outer shape no problem.
I lost one drill bit, due to not giving any coolant fluid.
The first cut out no problem.
But for the second cut out there was a hidden failure in the PVC sheet.
I have made two holes at the wrong place, see marked in picture 07.
So when the cutter passes this place I have lost the vacuum and the part came loose.
Next idea, a new attempt and to use the help of an additional clamp.
But it failed again. There are to much shear forces, the one and only clamp could not resist.
The very last picture does show the main problem.
Left hand side, marked in blue, are 3 holes in the PVC sheet to transfer the force to the work piece.
Right hand side, red marked, I can not make the same holes, due to the grid of the table. It does not match.
So here is a clear limit for using this clamping technologies with this application.

[fumopuc]

A Plan B was necessary to salvage the part.
I have put it into the vice and did a new set up by finding the center of the other big hole.
But unfortunately the result was not as expected.
The new made hole was not round and seems to be out of center.
First I have been complete at a loss. But the inspection of the mill has shown the reason for this mess.
This little cut out piece of brass, pic 14, from an earlier operation has fallen behind the table into the slot between table and column of the CNC mill.
Covered in that red silicon sheet, which is for swarf protection there.
The table had to go very close to column during the CNC milling operation and very close to the end of the necessary movement for that hole to machine, it was blocked by this little piece of brass.
I do not have a closed loop system at my CNC mill, so some steps has been lost and the controller did not know that.
The result, two parts for the the bin, no salvage.
Additional the cutter has hit one of the parallels.
VHM cutters do not like the high speed contact with steel.
See picture below.
A new one to compare how it should look like.