Need a new engine?/Mechanical porn

[sAsLEX]

and
http://www.youtube.com/watch?v=GU32Q6QXtWQ

[The Pastor]

THats pretty trick,.

[kneescraper]

Very trick, would those shavings not get in the way in the bores. I would have thought they would spray cutting fluid on the bores while machinning.

[Conquiztador]

Might be time to upgrade from the casting in the sand box...

[shcabbeh]

Damn, that's sweet.

And I thought they just poured the metal into a big engine shaped box.

[k14]

Very trick, would those shavings not get in the way in the bores. I would have thought they would spray cutting fluid on the bores while machinning.

The bores will be pressed into it I'd imagine. Don't know how well aluminium bores work?

Damn, that's sweet.

And I thought they just poured the metal into a big engine shaped box.

99% of engine blocks are cast. Do you know how expensive a chunk of alu that big would be?? I reckon in the vacinity of $10k. All the shards are waste, can't be used again. Out of the original block I'd say over 50% would be wasted.

[Mr. Peanut]

How does the machine see where it's going with all that milky shit everywhere? p/t

[shcabbeh]

99% of engine blocks are cast. Do you know how expensive a chunk of alu that big would be?? I reckon in the vacinity of $10k. All the shards are waste, can't be used again. Out of the original block I'd say over 50% would be wasted.

So what are the advantages of making it that way? Or is it just that aluminium has to be done like that?

I would have thought the use of machinery like that would be more expensive than casting, but just speculating here.

[avgas]

So what are the advantages of making it that way? Or is it just that aluminium has to be done like that?
I would have thought the use of machinery like that would be more expensive than casting, but just speculating here.

Yep way more expensive. But accurate to a few microns.

[Zapf]

So what are the advantages of making it that way? Or is it just that aluminium has to be done like that?

I would have thought the use of machinery like that would be more expensive than casting, but just speculating here.

I would say for low volume production or for development testing. Amazing how far CAD/CAM has come.

[Zapf]

How does the machine see where it's going with all that milky shit everywhere? p/t

It doesn't need to see. The steps are all programmed and tested inside the PC as simulations before the job.

[swbarnett]

All the shards are waste, can't be used again.

Can't they be pooled and remelted into a new block?

[sAsLEX]

Very trick, would those shavings not get in the way in the bores. I would have thought they would spray cutting fluid on the bores while machinning.

There is a hole in the bottom once they start the finer stuff and they tip the piece to remove them at times as well, and they spray all the "big mind blank here" liquid about the place to help remove the swarf.





Prototyping would be the only time, or one offs, that I would see this being done.

[Sketchy_Racer]

very cool.

The only reason they would machine a solid billet block, is as mentioned, either a prototype, but even then, I doubt it would be more cost effective to do it that way. and there are always unknowns when you make something out of a casting rather than a billet.

Im picking this particular example was mainly to show an example of what this machine is capable.

Also, in case you're wondering what the 'dancing' effect is,

A finish is always more accurate, and a nice finish when the tool is perpendicular to the work. As it appears they are milling out the bores for a cast iron sleeve to be pressed in, it needs to be a consistent, accurate finish.

Now, to give an idea of cost of an item like this in NZ.

It took 119 hours of solid machine time (not including setup/screwups or programming)

We charge out our CNC's at work at $160 p/h

= $19,040 of just machine time, let alone other time.

Very expensive engine block yes!

[slowpoke]

As it appears they are milling out the bores for a cast iron sleeve to be pressed in, it needs to be a consistent, accurate finish.

I dunno, but I wonder if they nickel plate the bores as per bikes, rather than pressing in liners?