Ohrndorf V12, new challange

[gerritv]

Beautiful work

gerrit

[petertha]

I'm so happy to see this project kicked off & look forward to the build. I also have the plans & modelled in CAD. Its on the 'one day' list. I built Ohrndorf's 5-cyl radial & there are quite a few part similarities to how he did things, even though the engine layout is obviously very different. There are not many V12 models so it will be very unique. Good luck!

[fumopuc]

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

Hi Mike,
Nothing changes so far.
My controller is Eding CNC and his software.
CAM is Fusion 360.

[fumopuc]

Beautiful work

gerrit

Thanks Gerrit, but it is a challenge.

[fumopuc]

I'm so happy to see this project kicked off & look forward to the build. I also have the plans & modelled in CAD. Its on the 'one day' list. I built Ohrndorf's 5-cyl radial & there are quite a few part similarities to how he did things, even though the engine layout is obviously very different. There are not many V12 models so it will be very unique. Good luck!

Thanks Peter
And yes, luck will be needed for sure.
It is a proven design, so I will try my best to copy it.
But it will not be easy.

[fumopuc]

Progress and setback also, is the headline for today.
I have drawn a cotter for 3D printing as a jig for the new set up of the block.

Also a very small one for the first trial fit, quickly printed in 10 Minutes.
But my attempt for the new set up has find a quick end.
I have been a bit distracted between, mails, the phone an some other issues, and instead of trying to find the reason why my block does not want turn some degrees, I have used some blind and stupid force.
Not good if Aluminium is running in Aluminium, yes there was some grease added, but in this case some chips has been find the way between the parts.
But I could save it, a black Edding a small grinder, the Dremel, some sanding and lots of patience has solved the problem at the end.

[fumopuc]

Next part, the pocket for the cam shaft.
At the end of that day, some more swarf.


I have been to fast in the corner with my 7,5 mm cutter in the 4 mm radius.
It does not hurt in this case here , but I took the opportunity to dive deeper and deeper into the software to find a solution and to understand it.
I have learned at lot, all details are available if you use the help function in Fusion360.
It is possible to "break" shortly in front of the corner and decrease the feet rate to what ever you want and the distance also.
In the picture shown as yellow line as part of the tool path.
At bit tricky if a smoothing is an integrated part of the operation also but all is possible.
In the second picture there are two blue lines without the yellow skid marks, but these pure finishing tool paths are generally much slower adjustable as the rest. 
With all this learned, I haven been able to get a precise final dimension of the pocket.

[fumopuc]

These cam shaft bearing blocks has been made long time ago as a successful experiment for this build.
And finally for the end of today, the holes for the liner.
Target was to get a diameter of 25,05 to 25,1 mm.
Some measurement, some minor adjusting and we have got it.

[Art K]

Achim,
Looking great! Just wanted to let you know that I'm following along.
Art

[Admiral_dk]

Great to see that you have overcome the problems presented so far 

.... and I do understand the feelings you get when you discover that your plans have to be corrected and then wondering if things can be saved ....

Per                  

[Roger B]

That's some fine metal carving  There's a lot of hidden technique to CNC machining 

[Dave Otto]

Nice progress Achim!

Dave

[fumopuc]

Art, Per, Roger and Dave,
thanks for watching, good to know that you are following along.


Today I had to make some holes and threading first.
Overall 27 holes with M3, 2 different depths.
Overall 1h and 15 minutes.
Threading alone, with the biggest part in 50 Minutes.
I do like this way of making threads you can go away a have a cup of coffee or tea.
If some thing will go wrong, no chance to access, you are a slave of this very thin cutter.

[Kim]

The block is looking great, Achim.  All those little tapped holes!  I can see the appeal of CNCing the threads, not to mention the whole rest of the block!  Nicely done! 

Kim

[fumopuc]

Next operation, to prepare the other part of the V, the deck for cylinder 1 to 6.
During the above mentioned threading operating I have had enough time to prepare the tool paths for it.
Changing the set up was no drama this time, using the 3D printed cotter as a jig again.