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Mike9311
Joined: 14 Dec 2004
Posts: 1678
Location: Chicago-ish
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 Posted: Fri Feb 27, 2015 3:53 am Post subject: |
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| ideola wrote: | | ideola wrote: | | Imagine what we'll be able to do when 3D printing with powdered metal can affordably produce components strong enough for an internal combustion engine. |
There. Fixed it.
One of my former clients mass produces using powdered metal, but not yet via printing. Iknow it's already possible, just not practical. Yet. |
One of the printers I looked at the only "affordable" powder was aluminum.
I also looked at DMG Mori Seiki which has an additive and subtractive (laser sintering head and milling) in one 5 axis package.
Shortly after IMTS this year Mazak released their new Integrex machine which is like the DMG but with two sintering heads and Milling/Turning (lathe). One for rough work and the other fine. This is considered multi-axis.
I forgot this one last night. GE bought Morris Tech for their 3D printing expertise in particular the metal stuff.
http://www.businessinsider.com/ge-buys-3d-printing-company-to-make-parts-for-jet-engines-2012-11
My stuff is technically backwoods when compared to what is cutting edge now. For now anyway
Here is the other link to that contest I mentioned. Interesting to see that most guys at similar final weights after FEA but a lot of designs differed
http://www.tctmagazine.com/software/ge-unveils-its-10-global-open-innovation-jet-engine-bracket-/
morghen, that would have been cool to see. You were basically exposed at the cutting edge of the tech
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1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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Mike9311
Joined: 14 Dec 2004
Posts: 1678
Location: Chicago-ish
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| Posted: Fri Feb 27, 2015 4:04 am Post subject: |
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here is another picture of a finish pass being made. Hopefully I got everything right. Its a strange part
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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brealytrent
Joined: 28 Dec 2008
Posts: 414
Location: Goldsboro, NC
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| Posted: Fri Feb 27, 2015 3:59 pm Post subject: |
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That's awesome
I didn't realize that aluminum ones weren't the norm. I'm 90% sure my 1980 has an aluminum one and it's not broken!
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1977 Porsche 924 - sold
1980 Porsche 931 - sold
1984 Porsche 928 'S2' Euro - sold
2016 Ford Fiesta ST - sold
2009 Porsche Cayman |
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Mike9311
Joined: 14 Dec 2004
Posts: 1678
Location: Chicago-ish
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| Posted: Sat Feb 28, 2015 4:13 am Post subject: |
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| brealytrent wrote: | That's awesome
I didn't realize that aluminum ones weren't the norm. I'm 90% sure my 1980 has an aluminum one and it's not broken! |
How come all you guys get the cool stuff! Here I am thinking this is rare.
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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Mike9311
Joined: 14 Dec 2004
Posts: 1678
Location: Chicago-ish
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| Posted: Sat Feb 28, 2015 6:40 am Post subject: |
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Looks like stock is 1156g and mine, according to CAD, is between 340-370g. I'll weigh the final piece once its out
I guess its approaching a kilo lighter but not exactly a kilo.
Just modeled a honeycomb underneath vs some drilled holes and slots in the base which is far easier to accomplish machining wise. The two ideas are essentially equal in weight loss.
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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Mike9311
Joined: 14 Dec 2004
Posts: 1678
Location: Chicago-ish
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| Posted: Thu Aug 04, 2016 11:22 pm Post subject: |
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Round 2 cued up
I never updated you guys. The first one had a mistake, or possibly two, which bummed me out big time. I am warming up for a much much bigger project proposed here previously so this needs to be right in order to proceed. Don't want to mess up a much larger piece of Al. Not to mention I am working with some updated tech that will increase productivity, hopefully anyway. BTW the chunk here is not as big as it looks
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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ideola
Joined: 01 Oct 2004
Posts: 15548
Location: Spring Lake MI
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| Posted: Fri Aug 05, 2016 12:31 am Post subject: |
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Impressive! I want to visit your shop!
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erstwhile owner of just about every 924 variant ever made |
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Mike9311
Joined: 14 Dec 2004
Posts: 1678
Location: Chicago-ish
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| Posted: Fri Aug 05, 2016 12:57 am Post subject: |
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| ideola wrote: | | Impressive! I want to visit your shop! |
Thanks!
You are more than welcome but first lets get you past 92Forty! I imagine you are getting busy?
If you need help the weekend before I could come up and lend some time and sweat?
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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ideola
Joined: 01 Oct 2004
Posts: 15548
Location: Spring Lake MI
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| Posted: Fri Aug 05, 2016 1:55 am Post subject: |
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| Mike9311 wrote: | | ideola wrote: | | Impressive! I want to visit your shop! |
Thanks!
You are more than welcome but first lets get you past 92Forty! I imagine you are getting busy?
If you need help the weekend before I could come up and lend some time and sweat? |
Indeed! I will take all the help I can get. Pencil me in for the weekend before, and we'll be in touch as the date gets closer.
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erstwhile owner of just about every 924 variant ever made |
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Mike9311
Joined: 14 Dec 2004
Posts: 1678
Location: Chicago-ish
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| Posted: Sat Aug 06, 2016 11:36 am Post subject: |
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Roughed...
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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ideola
Joined: 01 Oct 2004
Posts: 15548
Location: Spring Lake MI
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| Posted: Sat Aug 06, 2016 1:23 pm Post subject: |
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Ooooooh, purdy! 
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Mike9311
Joined: 14 Dec 2004
Posts: 1678
Location: Chicago-ish
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| Posted: Mon Aug 08, 2016 1:54 am Post subject: |
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Now I am moving from the basic roughing, which I tried to keep simple, to re-roughing. This is where I move in in places to take out material that is not as easy to get to from above. I am playing around a bit here and am constantly changing things as I go along, either virtually in simulation or on the actual mount. In the end I want to keep it simple for the sake of speed.
Here is a short vid. I already cut the section with coolant and then re-ran it for the vid without coolant. This still leaves a bit of material behind for final finishing. I likely will not go crazy with the finish in places where it doesn't matter.
https://vimeo.com/177913273
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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Mike9311
Joined: 14 Dec 2004
Posts: 1678
Location: Chicago-ish
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| Posted: Wed Aug 10, 2016 6:28 am Post subject: |
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another vid...
https://vimeo.com/178240128
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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ideola
Joined: 01 Oct 2004
Posts: 15548
Location: Spring Lake MI
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| Posted: Wed Aug 10, 2016 6:33 am Post subject: |
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Man that is cool. How many hours does it take to turn a block of Alu into that!!!
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erstwhile owner of just about every 924 variant ever made |
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Mike9311
Joined: 14 Dec 2004
Posts: 1678
Location: Chicago-ish
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| Posted: Wed Aug 10, 2016 7:55 am Post subject: |
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| ideola wrote: | | Man that is cool. How many hours does it take to turn a block of Alu into that!!! |
I am a kid in a candy store watching this stuff myself....
Time: That's what I am figuring out I am playing it safe and checking almost each step by itself.
To answer the question directly, the main roughed out piece took 2.5 hours but I played it safe. Too safe actually were I annoyed myself watching it do something painfully slow. BTW this is so much faster than my first one I didn't finish but I am expecting to get the time down even further by a lot. Sometimes something that takes an hour can be cut to 10 minutes.
I always do it this way with hopes of preventing a crash or an issue I did not catch in simulation. Trust me, I just caught a big one before it did anything to the part. Now I can go back and tune (fix) the program that processes the code for the machine. If I make the part again, I will go faster. If there is a the 3rd or forth part, I expect to be flying !!
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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