Author Topic: A CI casting from 3D mould  (Read 803 times)

Offline IanM

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A CI casting from 3D mould
« on: September 26, 2022, 03:40:13 PM »
I am trying to build a ca 25cc Midget 4 stroke engine from Popular Mechanics 1936 articles, and advice from a previous builder. As part of that I wanted/needed a machinable cast iron cylinder barrel casting. I found a UK foundry William Lane Foundry, Middlesborough, UK and they were happy to work with me on this small order. I produced a 3D print for the mould halves, and they cast it. Very fair pricing and if this works out, I'll be back for more. Photo of mould pairs and the out-turn casting is included.  Ian M

Offline jirvin_4505

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Re: A CI casting from 3D mould
« Reply #1 on: September 26, 2022, 04:29:41 PM »
Seems Midget 1936 is popular this month

Very nice casting. If I lived in your country I would be in on your order

Iím planning on aluminium with liner Ö that is until I can find somebody local Australia to do a cast iron cylinder

Cheers Jeff
Looking forward to the build

Offline IanM

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Re: A CI casting from 3D mould
« Reply #2 on: September 26, 2022, 07:16:30 PM »
Jeff

If you would like the file for the mould I can send it. The CI casting was £50 plus £8 to post to me. If you are tempted with Aussie post, let me know. Would you be prepared to share your crank case 3d model so I could AL cast that here?

Happy to compare notes as the Midgets develop.

Best regards

Ian

Online Jasonb

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Re: A CI casting from 3D mould
« Reply #3 on: September 26, 2022, 07:45:28 PM »
Jeff it would be a lot cheaper to just use some 75mm round or 55mm square cast iron bar, it's not as though the casting has the fins cast in so you are only saving a small amount of lathe work and will be sure of sound material.

Cost here would be about £12 rather than the £50 Ian paid

Offline IanM

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Re: A CI casting from 3D mould
« Reply #4 on: September 26, 2022, 08:58:31 PM »
Good point - maybe I should have gone this route. We'll see how good the material is in a bit...

Offline jirvin_4505

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Re: A CI casting from 3D mould
« Reply #5 on: September 27, 2022, 12:28:10 AM »
Jeff

If you would like the file for the mould I can send it. The CI casting was £50 plus £8 to post to me. If you are tempted with Aussie post, let me know. Would you be prepared to share your crank case 3d model so I could AL cast that here?

Happy to compare notes as the Midgets develop.

Best regards

Ian

Yep very happy to share
Will post fusion 360 link after work
Warning.  Iím very new to 3D drawing so checking my work is well advised
I will also have a go at posting the stl in thingaverse

The drawings are my conversion of the scans imperial measurements into mm

In hindsight I probably should of drawn in the imperial units and let the 360 do the conversion

Cheers Jeff

Offline jirvin_4505

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Re: A CI casting from 3D mould
« Reply #6 on: September 27, 2022, 12:30:49 AM »
Jeff it would be a lot cheaper to just use some 75mm round or 55mm square cast iron bar, it's not as though the casting has the fins cast in so you are only saving a small amount of lathe work and will be sure of sound material.

Cost here would be about £12 rather than the £50 Ian paid

Good advice Jason. Will see what I can find

Cheers Jeff

Offline jirvin_4505

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Re: A CI casting from 3D mould
« Reply #7 on: September 27, 2022, 01:12:42 AM »
Posted links to drawings in my build thread Reply #7

https://www.modelenginemaker.com/index.php?topic=11017

Enjoy  :praise2:

Cheers Jeff

Offline IanM

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Re: A CI casting from 3D mould
« Reply #8 on: September 27, 2022, 10:21:49 AM »
Jeff

Much appreciated - thank you. I reckon they look very good.

Regards

Ian

Offline IanM

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Re: A CI casting from 3D mould
« Reply #9 on: September 27, 2022, 06:31:27 PM »
 :praise2:

Jeff

Those file links were superb. Understatement of the day. I have happily started to print from them for my other castings. That is a quite exceptional boost for my and I daresay a few other Midgets.

Thank you

Ian

Offline IanM

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Re: A CI casting from 3D mould
« Reply #10 on: September 28, 2022, 08:00:43 AM »
Jeff

I had a look at the video clips of your aluminium casting - results look good. A question, do I assume you were using a split half sand cast mould eg for crankcase rear or were you doing something different?  The reason I ask is that in the clip you have a collection of spare 3d printed moulds and I am wondering if in some way they are consumable ie were you printing in a filament that allowed you to try (succeed) in investment casting the piece.  My bet has to be split sand cast mould but I thought I'd ask.

Very happily printing the files you shared.

Regards

Ian

Offline jirvin_4505

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Re: A CI casting from 3D mould
« Reply #11 on: September 28, 2022, 09:32:16 AM »
Glad you are enjoying the drawings. This is what I enjoy about forums. Sharing what we have

Iím using the patterns for traditional drag and cope sand Molds

The interactions of the patterns with shrinkage and ability to release from sand Ďinvitedí opportunity to redo the patterns as I learnt what worked

Main problems accounted for was the proper spacing in the crankcase patterns for the selected gears

With the head I drew it as best converting from inch to mm then had to account for what looked to be shortages in machining allowances and obvious tight spots with the sand mold

Again double check against the pattern plans ,,, remember Iím very new at this

Cheers Jeff

Offline IanM

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Re: A CI casting from 3D mould
« Reply #12 on: September 28, 2022, 10:50:25 AM »
Jeff

Thank you, and that all makes perfect sense. I appreciate the gear centre line distance concern. I had that on another design and tried, with some success, to adjust the gear tooth numbers to end up with a different centre line distance. So, that assumes you make your gears, which may not be convenient at this stage but I only mention it as it ended up being a helpful 'way out' for me.

I think your casting developments look great, and I like the draw features on your mould designs.

Regards

Ian

 

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