Ohrndorf V12, new challange

[Dave Otto]

Hi Achim

Cool, a new project and off to a great start too!
Looking forward to following along with your build.

Dave

[Admiral_dk]

I have admittedly not chimed in yet - But as I'm very much an IC man myself - this is one of the more interesting builds here 

I'm already paying attention to how you make and use the Jigs needed to build this Engine 

Per   

[fumopuc]

Sounds like an impressive engine!  Do you have a picture of what it will look like?
Watching along!

Hi Chris, thanks for popping in.
here are some pictures and videos also.
https://www.engineman.de/product/plan-12-cylinder-v-engine/?lang=en
There was a video of an American guy at YouTube, showing a test run at a show, but I can´t find it anymore.

Wow - thats fantastic!

I have just find the missed video again.
https://youtu.be/mNPYjf1RIko?si=37hA112K4uVOxeJo

[fumopuc]

And more fixuture and jig preparation today.

But theories and reality seems to be close.
At the right side, close to the tool length sensor, I had to fight for each millimeter.
The result is that left hand side, I have enough space now to use my 10 mm mini bearing probe.
Target is to check left hand and right hand side with pins if it is parallel adjusted to the X axis.
I am close to the machine Zero there, only 1 or 2 mm space, but that should be fine.
A check with a cutter has shown, there is still enough space right hand side to drive to the tool sensor without any collision.

[Kim]

You're certainly making the most of your work envelope! 

Kim

[fumopuc]

Thanks Kim. Still fighting with the set up, but coming closer.


There was an additional machining necessary to give some space for later milling inside the crankcase.
That done both sides, given the opportunity now for the first real fixation of all at the mill.
After a small adjustment with additional shims left hand side, I archived a parallelism to the X axis with a deviation from 0,02 mm, measured at the two pins.
For me that is fine and nearly perfect.

[fumopuc]

Next issue to attack, the self made bracket to carry the movable chips protection.
It does no fit anymore, the supporting surface is partly gone.
The CAD model is still available and with some quick and dirty cutting and adding new volume I could get something new to send to the 3D printer.

[gerritv]

Excellent setup. It seems very sturdy for the carving to come.
I hope you don't need that milling machine for anything else for a while. I just had to dismantle a setup to make some more t-nuts :-(

gerrit

[Dave Otto]

Great idea on the swarf shield, I'm thinking I may make something like that for my mill.

Dave

[fumopuc]

Great idea on the swarf shield, I'm thinking I may make something like that for my mill.

Dave

Hi Dave, yes this little shield is very usefully.

[fumopuc]

Excellent setup. It seems very sturdy for the carving to come.
I hope you don't need that milling machine for anything else for a while. I just had to dismantle a setup to make some more t-nuts :-(

gerrit

Thanks Gerrit, and yes it will be a longer journey.

[fumopuc]

At the end of this day we have had some swarf hills under the mill table.
Today the first operations have been made.
Nibbling step by step and deeper and deeper into this lump of aluminium.
tbc ...

[fumopuc]

... and some more pictures.
And still a lot to do.

[fumopuc]

There was a little challenge to tell the CAM software about the M10 thread rod in the crankshaft center line.
So far the computer didn´t know about it.
Some parts of the fixture, the round pieces left and right hand side has been already known to him, but not the rod, so I have to told him about it.
Some time ago, I have seen that there will be a cutter with min 31 mm work face will be needed.
I have got a VMH cutter d=10 with 32 mm.
Not my standard size for the little CNC mill, so a good quality ER20 collet with less run out was also purchased.
Than I was fighting with the tool path and tried to check everything very accurate with the simulation.
At the end it was possible to guide the cutter close by, but not in the threaded rod, here marked with a red circle.
Also in the lowest level at the end no collision anymore.
After this was done, the outer parts has been shaped again.
And some holes and M3 threading.

[Vixen]

Hello Achim,

That's some very nice CNC carving going on.

Yes, CNC does exactly what you tell it to do, your job is to tell it what to do and what bits to avoid.  I think we both enjoy that challenge.

What CAM program do you use? Also what is your CNC driver software?

Cheers   

Mike