Creative Fixturing to CNC Machine a Motorcycle Oil Tank! WW111
Вставка
- Опубліковано 20 вер 2024
- This chunk of aluminum is a leftover part from an automotive adapter plate. The customer, Todd Perkins, wants to use it for the oil tank in a lightweight hybrid motorcycle (more info below). We use Fusion 360, the Tormach and some creative fixturing to shell out the part!
More on the Motorcycle Project:
The project is based on one of Nic's Ythos Motorbikes chassis. The goal for the bike, beyond being a totally insane street chopper, is to be a thoroughbred straight line race bike; ultimately with a 400hp/400lb, 1:1, power-to-weight ratio. End goals there are ~8-sec 1/4 mile ETs, and 200+mph top speed. Power will come from a proprietary fuel-electric hybrid drive system. The fuel part is an ethanol burning 96 cu-in/1600cc American V-twin, that will be nitrous-injected to reach the desired end goals. Instead of a convention transmission, Scrape runs an AC electric motor, capable of 100 lb-ft of torque from 0 rpm, that will accelerate the bike from a standing start until the V-twin phases in and takes over. One speed, twist and go, from 0 to whatever. It will also be able to re-charge its small battery pack on the fly, via the power of the V-twin and regen capability of the AC motor; or plug in and charge.
~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Recent Videos:
Form, Cut or Mill Threads: bit.ly/1nHBnrx
Fusion 360 1-2-3 Block: bit.ly/21qgq1y
~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Reach us / CNC Info:
Speeds & Feeds: provencut.com
Download Fusion 360: www.dpbolvw.ne...
Online Fusion 360 Training: bit.ly/LearnFus...
Hands-On CNC Classes: www.nyccnc.com...
SMW Products: saundersmachin...
CNC Resources: www.nyccnc.com
Music copyrighted by John Saunders 5 Reasons to Use a Fixture Plate on Your CNC Machine: bit.ly/3sNA4uH
Excellent work, love watching your workflow and how you set things up. Always learn something, thanks for sharing!
I came here to see a bike for World War 3. :-) Turned out nice and I am impressed you are confident enough to run lights out on a first run of a job.
For all those asking about the weight reduction: I didn't weigh the part before John performed his magic, so I modeled the original part (pre-SMW machining). I didn't remove the two holes and fluted counterbores John cut for us, so the actual weight saving is a matter of ounces more than these numbers. Original (CAD weight) part was ~4.2707lbs (+material in 2 holes and counterbores). CAD model John machined from is 1.8827lbs (in CAD). Weight savings (not including 2 holes and counterbores) = 2.388lbs. It does feel like it is less than half the original weight.
Couldn't take it. If you're as anal as I am and just had to know: the fluted counterbores (yes, I modeled one) weigh 0.333lbs (in CAD), so 0.666lbs for both. That means the total weigh savings (according to the CAD models) is 2.4546lbs. ;-)
8:49 focus you fack
ave crew unite
I caught that too. Works every time! LOL
I totally finished that one in my head too... Too much AvE :D
I would highly recommend looking into get/making machinist jacks. It would have saved you the trouble of making those spacer blocks. Real ones are nice with the different top pads that swivel but they are easy to make quick and dirty ones using a pipe coupler, some washers, a nut and various length bolts to give you low profile up to a decent height cheaply. They are very useful if you have a long piece in a vice and are drilling holes in a part that is cantilevered out. Designing and doing the fusion 360 of a decent set, then machining them like you did with the clamps might be an interesting set of videos. Just a suggestion.
I've also get the first thought about machinist jacks
cncua must have for parts that don't sit flat and need that extra support
John, I like your quick and simple shim washers. I've made some similar using the carbide disc punch sets you'd find at the 'freight store, or off of Amazon. Works nice to knock out the inner hole then eyeball it for the OD shape especially if you need it offset along a wall. They don't like
Very good job thanks for sharing
Nice job John😀
John, you have to see if customer will let you do follow up video of this bike. Really hard to believe that it will only weigh 400 lbs when done. Would be great to see it and how they adapted your part into it. Nice job on the part by the way.
An Aprilla RSV4 with 205 HP stock has a dry weight of 398lb that's with fairings and stuff as well.
Striped down and modified to reach 400hp within 400lbs isn't a huge stretch.
Interesting part to hold. Have you ever used low melt plastic to custom form a support for irregular parts? This stuff works well in conjunction with other clamping systems and tends to dampen harmonic chattering. Its one draw back is you can't hard mill or otherwise put too much heat into the part. It melts in a double boiler at about 60C
Awsome the Wednesday widgets are getting allot more oddball. I can wait for you to get a real VMC like john Grismo then shit will get serious, Great job as always
nice way to go with the light's out run :)
For the timelapse shot, it seems you have two different lights inside the mill enclosure, one close to the camera and one in the far corner. The one close to the camera is a nice white well balanced with the rest of the shop lights, but the one away looks really yellow. On one hand the color difference might give some volume to the parts (because different specular reflections will have different colors), but that yellow doesn't look very nice.
This was pretty slick and impressive, but if it needed to be reduced to the thickness of sheet metal why didn't you just make it out of sheet metal in the first place?
Great video. I probably spend about 50% of my time at the mill fixturing. Some of the setups a pretty weird looking but to date no slippage issues. (knock on titanium)..
way to go mate!
I have a question (I don't do this type of work at all). Why on your passes to shave metal off do you only go one direction instead of going one way move the bit in and go back the other way?
HSM adaptive cuts or really any highspeed toolpaths should be done in climb milling only.
Adaptive cuts rely on maintaining cutting angles and chip loads. Reversing the cut direction changes the cutting angle.
Plus climb milling takes about 50% less power to make a cut vs conventional milling. And those mills are already starved for HP as it is.
Nice job fixturing. That's always the challenge for me. I tend to use a lot of Monster Jaws, but for smaller parts. Your long stickout milling went really smoothly. No matter what bit I use, I'm unable to finish tall edges like this (~6:00 on your vid). I always get horrendous chatter.
Great video John!
Did you record how you did the programing? This piece has some complicated curves and radius thought it would be interesting on how you figured it all out.
Thanks
Love this video John time lapse pure enjoyable keep the content coming. Idea for ya how about setting up a IP web cam to monitor and stream it live to a webpage? that way when you cant there you can monitor it remotely.
you need a handheld 3d scanner for jobs like that, it would save you time
John, nice job keeping a consistent wall thickness around that complex curve. It would be interesting to see how you measured the material shape and then programmed that. Or did you have CAD files from then the original part was made?
-- Mike
Beautiful finish, it would have been interesting to see how much weight was removed.
i want to see more of that 80% 9mm on your desk john....
Humor me - did you weigh the part before and after? Not my project so I don't need to know the numbers. Just curious.
I saw your vid with the USB control for your pumps, and I thought that you could use something like that to control the on off function remotely, meaning you mentioned you ran this part lights out, why not setup a webcam stream of the part running on the machine so you can watch from the diner table and if something messes up you can hit a stop button on a remote app. This way you can remotely watch the run, even if you are in the other room in the shop. I am sure Ave and you could team up on such a project that would be swett, a CNC webcam / control app, Just a thought.
We have this at our shop on a few of the 5 axis mills. One cam above the spindle (it's a HBM) and one at the controls. That way, when we are at the other end of the plant (2-3min walk) we can pull it up quickly at any computer in the plant and check on it, or on our phones while we are out to lunch or something. Very helpful to keep machines running.
Did you have to replicate this part in fusion 360 first? If so I'd love to see how you were able to accurately reproduce those fairly complex curves.
How much lighter in weight did it end up after that nice Job?...:):)
john nice work.=========bob
thats mad bugger riding that
have you ever done any head work (engine heads) on your tormach? fixturing made me think of that.
great job! hear you watch AvE as well.. cheers.
What is the purpose of the shape of the beginning & ending of the cutter path when doing the major material removal (say, at 4:15 and 4:26)? Less abrupt change in chip loading?
How do you locate something like that? Do you just pick a point on the piece and locate it with a wigler?
What was the weight of metal removed? Like what were the before and after weights?
Love the work man! Beautiful.
I have been trying to figure out what that music is you use for your timelapse starting at 12min 21sec, could you let me know what it is called?
Did you neck that Shear Hog?
How much weight did it end up saving?
So John, how much weight did you shave off, do you know?
Can you please make a video about how is it possible to work
on a piece that is not just a block of aluminum, but is a
part for ex. that you modify on the mill?....That would be interesting, thanks!
A few ways. It appears it's a full 180 arc. And the two flats are parallel. Tram those in straight along the X axis kinda like a vice.
XY zero can come off of one of the existing holes in the part. Z zero you can use the top of the flat area he's removing.
Considering it's only weight reduction and nothing high accuracy, the fixture plate and bolts used to hold it down were probably adequate for alignment.
thanks for the info buddy!!
What was the weight of the part before and after the machining?
👍👍
hey John, how did you go about doing the CAD on this part?
When will you upgrade to a more professional mill? I'm sure that the Tormachs are great for hobby stuff, but you're running a business now.
Hello everybody!
want to see u put cam on that piece how boundaries work i sems to have trouble with that in inventor hsm... dont quite understand:)
makes sense to me
I'm confused... how is that an oil tank?
Sebastiaan, it's the front upper half of the tank. The other sections of the tank will be hand-formed, machined, and maybe printed, then all welded up.