More FI parts in solidworks

[davegt27]

I am supposed to make this on the CNC tonight but i've been stuck for the last 2hrs just trying to make a drawing of the dang thing

I am trying to get the instructor to add inventor but auto desk so i can try it
solid works is a very painful program

anyway 2.2 intake flange (took 3 days to make ha ha)

[Paul]

Dave,

What material thickness are planning to make this from? Do you have a dimensioned sketch? Even one that has been hand drawn? I can draw it in 2-D in Auto-Cad... or better Yet cut you one on the Water Jet at work...

Lemme Know

[RallyBob]

Don't forget that the flange can't have those through-holes for mounting or they will overlap with the exhaust manifold. They need to be half-moon.

[keithrulz]

i agree autodesk inventor is easier but if you think solidworks is a pain try Pro/E

[deanh74_2]

Originally Posted by keithrulz i agree autodest inventor is easier but if you think solidworks is a pain try Pro/E

Keith,

Have you tried using Usless... er... I mean UniGraphics NX? that is a pain in the $%#.

Dean

[keithrulz]

No i haven't run unigraphics, but i hear it's as bad as you say.

[deanh74_2]

They have just started using it here at my job. It has been a real pain. AND unfortunetly it is just about the only system we can run...

Dean

[davegt27]

Originally Posted by Paul Dave, What material thickness are planning to make this from? Do you have a dimensioned sketch? Even one that has been hand drawn? I can draw it in 2-D in Auto-Cad... or better Yet cut you one on the Water Jet at work... Lemme Know

Paul i forgot my thumb drive but i will get the info
i finally figured out how to do a drawing (you have to open up a blank drawing and import your part)

Don't forget that the flange can't have those through-holes for mounting or they will overlap with the exhaust manifold. They need to be half-moon.

Bob i have to put the holes there so i can bolt it to the fixture

the Solidworks works off relations to one another so you cant just go in and change one line

I started version "D" this time everything is coming from the dowel pin


thanks
David

[hustlerzlife]

We use Solidedge here at school and it seems pretty straight forward. Might wanna see about using it instead.

[davegt27]

Thanks for the info I found solid edge’s web sight but I can't tell too much from it

Well I finally got the drawing right at the end of class on Thursday

They have these things called radius gages to find the radius of different items. 1/2" was the biggest they had so I took to using different size sockets

One of the young kids in the shop helped me when he measured the size of the socket with some calipers, I was like Doh! The outside diameter of the socket not the size of the socket you dummy (talking to my self) ha ha

I am going to use 1/2 inch plate. I only had a few min of class time to upload this image so it’s not so hot




Davegt27

[RallyBob]

Dave, I have a suggestion, but don't know if it is something that you can do with the equipment available to you.

Have you considered making the port openings on your flange angled 'upward' to coincide with the roof of the 2.2/2.4 intake ports? This way instead of having a port that angles upward, then goes horizontal for 1/2", then angles upward again....you have a smooth transition from port to intake runner.

I'm also curious if you are going to keep the port shape symmetrical or if you're going to change the upper radii to match the stock head castings (which are asymmetrical from top to bottom). If the radii on the flange are smaller than the OEM port opening shape, then there will be quite a bit of turbulence due to the interference.

Bob

[davegt27]

Have you considered making the port openings on your flange angled 'upward' to coincide with the roof of the 2.2/2.4 intake ports? This way instead of having a port that angles upward, then goes horizontal for 1/2", then angles upward again....you have a smooth transition from port to intake runner.

I can have the CNC take an angle cut so I was going to have the cut angled at the top
the instructor said to just do a 2D drawing and we can get it cut out pretty easy

one of the you kids in the class (the same one that made me see the light on measuring the outside diameter of the socket) jumped up on feature cam and had a 2d drawing done in a 1/2 hour that was pretty close
he also did a tool path simulation which was pretty cool

I'm also curious if you are going to keep the port shape symmetrical or if you're going to change the upper radii to match the stock head castings (which are asymmetrical from top to bottom). If the radii on the flange are smaller than the OEM port opening shape, then there will be quite a bit of turbulence due to the interference.

OK you just lost me; I know the gasket had some flats at the top instead of the rounded radius.

Other then that my drawing matches the gasket almost exactly

Let me try to upload a scan

Davegt27

[RallyBob]

Originally Posted by davegt27 OK you just lost me; I know the gasket had some flats at the top instead of the rounded radius. Other then that my drawing matches the gasket almost exactly

Here's a pic of an intake for a 3.0 head (same ports as 2.2 and 2.4). You can see that the lower corners of the intake ports have a relatively tight radius, similar to a 1.9 intake port. But the top corners of the intake port have a bigger radius, so the intake ports look a little bit like a 'tunnel' in the side of a mountain, if you know what I mean. A bit more square at the bottom, and a bit more rounded at the top.

[davegt27]

OK I see

I have a copy of my final drawing and I just laid the 2.2 gasket on top of it

The top of the intake port, I made it match the bottom which means I opened up the tops radius a little (it starts out as two radii)

The radius I have for the bottom is .406

Ht of the port I have 1.582

I can’t get Photobucket to work so I can’t show you a scan

David

[Tru-Craft]

David, looks like your learning alot.
The CNC machining trade can be fun/challenging.

What CNC machine are you using?
How are you going to generate the G-code program?
Have you got a machining plan yet?
How are you planning to hold the 1/2" plate?
What are you going to machine first?
What size end mill?

I have a few ideas, but want to see how they/you want to do it.

It's a perfect first CNC project to learn on, have fun!

Oh, remember to lock out the "Z" axis when testing the program the first time!
Lyle

[davegt27]

What CNC machine are you using?

They have 3 Haas CNC machines

http://www.haascnc.com/VMC_MODEL_HIG...p#VMCTreeModel

How are you going to generate the G-code program?

I had the chance to sit in on one of the G-code classes but I don't think I will be generating G-code for this project

Have you got a machining plan yet?

If you mean have I figured out the tool paths then no.

How are you planning to hold the 1/2" plate?

The first step I did was to make a fixture on the manual mil.
I guess I need to drill and tap some holes in the fixture next.

What are you going to machine first? What size end mill?

Not sure I think the next step is to export the drawing to Feature Cam so I can figure out the tools and the tool paths (then it goes to master cam I think)

Solidworks is pretty cool but hard and frustrating. I can now see why it cost so much to get things done.

I have started work on the throttle body flange and its even harder then the head side


David

[davegt27]

The drawing gets exported to master cam

My instructor wrote the program and worked out the tool paths

Program took 8 min to run

This is the end part






David

[oldopelguy]

Originally Posted by davegt27 This is the end part

But I need 5 of them David, you didn't make enough....

[RallyBob]

Very cool parts Dave!

[davegt27]

thanks guys

pretty cool being able to get stuff done

working on the TB flange now

Davegt27

[davegt27]

DCOE flange made in Solidworks

this one was pretty easy compared to the one I been working on for months

but I am starting to learn this stuff





now that I am learning I should be able to go back and modify the 2.2 flange
to the asymmetrical that Rally Bob mentioned

the reason I only made two sets of flanges is that all the aluminum I had

next comes matting the 2.2 and other flanges to make some type of manifold

the DCOE one is for a friend that wants a DCOE to RB26 TB adapter ha ha but once done I hope to do all kinds of stuff

Davegt27

[BQS4]

Very cool Dave!!

[davegt27]

ok the latest part DCOE to RB adapter





davegt27