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Sam Moss
Joined: 28 Aug 2012
Posts: 16
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 Posted: Fri Oct 05, 2012 3:03 pm Post subject: Cylinder Manufacturing |
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After a long time lurking here I thought I'd best join.
Not the simplest of questions but does a cylinder design like we use in karts and motorcylces have to be a sand cast or can it be fully machined from billet 
If it can't be fully machined from a billet in could you say machine it to a 70mm bore to mill all the port edges on a CR250 cylinder and sleeve it to create the inner walls of the ports |
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Sam Zavaglia
Joined: 23 Nov 2004
Posts: 1189
Location: Australia, Sydney,
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| Posted: Fri Oct 05, 2012 3:59 pm Post subject: |
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Can any CNC machine make the exact porting angles and water jackets required from a single piece of billet?
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Greg Lindahl
Joined: 13 Jan 2011
Posts: 267
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| Posted: Fri Oct 05, 2012 4:15 pm Post subject: |
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Mill the ports from the outside and cover the holes with a 360 degree collar.
Sure, you could make cylinders. You could also have them built additively as was done by at least one 125 GP team until this year. |
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Chris Reinhardt
Joined: 29 Aug 2002
Posts: 2933
Location: United States, New York, Ossining
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Sam Moss
Joined: 28 Aug 2012
Posts: 16
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| Posted: Sat Oct 06, 2012 11:33 am Post subject: |
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| Greg Lindahl wrote: | Mill the ports from the outside and cover the holes with a 360 degree collar.
Sure, you could make cylinders. You could also have them built additively as was done by at least one 125 GP team until this year. |
How do you mean additively? 
Chris that is pretty much how I'd imagined it by milling the outside port walls and using the sleeve to create the inner walls.
My wondering was how important is the inner wall shape? Is it just used to separate the ports from the main bore or is the design more complex and used to guide the fuel towards the outer edge of the ports. |
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Chris Reinhardt
Joined: 29 Aug 2002
Posts: 2933
Location: United States, New York, Ossining
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| Posted: Sat Oct 06, 2012 2:54 pm Post subject: |
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Your 2nd answer!!! The transfers are design to push the charge back and down. From my understanding it's to counteract the exhaust flow going out the cylinder, the higher up in the rpm it operates, the more exaggerated the direction.
The post is from this year, I would register on that site and send that guy a message...
CR
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East Coast Super Kart Series
"This is how we roll!"
www.eastcoastsuperkart.webs.com
CR2 Motorsports
"Home of Cobalt Superkarts"
www.CR2MotorSports.webs.com |
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james jackson
Joined: 02 Dec 2007
Posts: 305
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| Posted: Sat Oct 06, 2012 6:21 pm Post subject: |
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| It is possible to rapid prototype cylinders in AL. It has been done before on moto gp bikes back in the late two stroke days on the BSL. |
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Greg Lindahl
Joined: 13 Jan 2011
Posts: 267
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Chris Reinhardt
Joined: 29 Aug 2002
Posts: 2933
Location: United States, New York, Ossining
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| Posted: Sat Oct 06, 2012 8:53 pm Post subject: |
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I was in Penske South shop in Mooresville, 6 or 8 years ago, my buddy is a chassis engineer. At that time they using 3D printers to grow foam plugs that were to be sprayed with a ceramic and then used for an investment casting. They also built plastic intake and cylinder runners with another 3D printer for analysis.
So I imagine that's how you could build a cylinder.....
CR
_________________
East Coast Super Kart Series
"This is how we roll!"
www.eastcoastsuperkart.webs.com
CR2 Motorsports
"Home of Cobalt Superkarts"
www.CR2MotorSports.webs.com |
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