2.2/2.5 big plenum custom intake GROUP BUY

[acannell]

Thank you TRYINGBE!! BTW what does trying-be mean???

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[acannell]

todays machining, at 8x speed! This is one of several setups, the actual machine time is 6 minutes.

https://vid.me/e/TQX

[moparzrule]

Pretty cool.

[GLHNSLHT2]

Are you not using coolant on the end mill because of filming the machining?

[acannell]

Are you not using coolant on the end mill because of filming the machining?

I try to avoid using coolant whenever possible..at least a couple notches above "preference" and more like "only if absolutely justified". My sump is pretty small and coolant is expensive even when I dilute it to the max at 35:1. So using it up means more inconvenience while I go mix up more and also more expense because it uses it up really fast..With all the splashing and atomizing once the stream hits the tool, very little of that coolant makes it back into the sump, especially when there are lots of chips in the enclosure and the coolant just sits around spread out over all those chips.

So if I have some reason to believe the cut isn't literally demanding it, I wont use it. That 0.344 cobalt drill definitely needs it. Without the coolant the same drilled hole stalls. The end mills though are another story. The 1/2" carbide 2 flute is so rigid and has so much chip clearance that it never needs coolant on 6061, at least at the max cutting rates my little mill can achieve. The 1/2" 4 flute hogging HSSCO thats plunging is barely taking any material off and is not cutting sideways, its not really under much stress in this situation. It generates tiny chips because of its hogging teeth so its pretty hard for it to build up any heat in the material. The only way I can get that one to stall is if I'm slotting with it and thats right at the edge of what I'd want to do with it given its huge stickout.

If there is a cut that I've spent hours trying to optimize and finally did, its the main bore. I still haven't got it quite right, and it comes close to stalling or does stall, but its very important to make it go as fast as possible because there is so much material to remove. First a about a 1.8" dia hole is bored at a 1 degree ramp spiral using a 1" 2 flute HSS end mill. Then its finished off with a 3 axis roughing. The hard part is that first boring at the 1 deg ramp. Flood coolant is useless as the cutter just blasts it right out. I tried setting up a misting coolant but I accidentally discovered that the spindle load went DOWN when I turned it off. And I tried it with water and coolant for the mist. Air blast seems to be the only thing that actually works, and I found that spindle load doesn't seem to change if I use it or not. I've got it down to just a few minutes of cutting time, but I have to stand there and watch the spindle load because it runs RIGHT on the edge of stalling. I think the problem is that the 1" end mill is too big for my mill to plunge even at 1 degree, and it ends up doing a lot of rubbing and creating a ton of heat and friction that doesn't go into the chips and ends up increasing the spindle load. I think I'm going to have to use a smaller end mill instead, something I can ramp at 2.5 degrees easily, but is still big enough and rigid enough to max out the spindle power. I have a 4 flute 3/4" HSS rougher I just got that I'm going to try out soon. Or maybe I'll just keep on standing there and watching things with the 1", since that requires less brain power.

[GLHNSLHT2]

hmmm, I would think tool life and cost would out weigh coolant price but then I don't have to buy it. 35:1 is extremely lean, we run ours at 8:1 but then our machines are much larger and cutting a lot more out at a time. The verticals run 3-6 of those flood nozzles you have, our Horizontals blast the stuff all over, and through the tool. You can take some massive cuts with them but it chews through 30-50 gallons of mixed coolant a day.

Looks good though, Was just curious as to your reasoning. Thanks.

[acannell]

hmmm, I would think tool life and cost would out weigh coolant price but then I don't have to buy it. 35:1 is extremely lean, we run ours at 8:1 but then our machines are much larger and cutting a lot more out at a time. The verticals run 3-6 of those flood nozzles you have, our Horizontals blast the stuff all over, and through the tool. You can take some massive cuts with them but it chews through 30-50 gallons of mixed coolant a day.

Looks good though, Was just curious as to your reasoning. Thanks.

Wow 30-50 gallons a day? Its hard for me to gauge what the tool costs really are..this is the first time I'm really pushing the mill and all the tools at a "commercial shop" work-level, at least in quantity. Right now a few of the tools in the list for the intakes are pretty worn...I think. I've used them for about 20 masi thermostat boxes and all the intake prototyping so far. The finish seems to be good still so I keep them in rotation. I'm not sure how much mileage is left in them. I'm also not sure if coolant would help or hurt. I think I'd need to go through alot of work to really get an idea whats what. The good thing is that all my tools are pretty cheap. The biggest carbide I use is a 2 flute 1/2" and those go for about $15 on ebay. The rest are run of the mill HSS or HSSCO and all pretty small. My most expensive tool that I actually use is probably the 7/16" Niagara ball mill. I think it was about $30 new! I really scrounge around on ebay to get deals on stuff. But my mill doesnt have enough power to justify carbides over 1/2" or exotic geometry aluminum or steel cutters. I tried one of those "super" aluminum cutters with insane MRR's but my mill cant keep up the chipload enough for the physics to work (whatever that is) so they just chatter alot and dont work.

[acannell]

First 12 flanges machined!

I have made huge optimizations to the toolpath, and I bet even more are possible. I dropped one section from 25 minutes down to 16.5 minutes!

[acannell]

89TonaVa...you're next on the BMF backup/future list!!

1. Vicus
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4. Shadow DEPOSIT RECEIVED
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31. 89TonaVa

[acannell]

Got the rest of the material! Got a fantastic deal from an out-of-state metal supplier, speedymetals.com . With all the cuts and shipping its still around $3.30 a lb!!! Thats only a buck more than surplus and way better then what you find on ebay. And I get all my pieces cut and ready to machine. My poor little bandsaw would die a thousand deaths trying to do all this. Plus they shipped USPS priority mail

And I got several plenum plates in-progress today!

[acannell]

Moparzrule, guess whos intake I'm welding on today??

[moparzrule]

Sweet

Kinda sounds like it may make it just in time to get it on before I get my engine in (keep getting delayed by things coming up that I need to get done around the house).

[acannell]

Thank you 88C/S!!

1. Vicus
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30. j4278h
31. 89TonaVa

[acannell]

Thank you POPE!!!

1. Vicus
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3. signsoflife22 aka knownenemy
4. Shadow DEPOSIT RECEIVED
5. Turbulence DEPOSIT RECEIVED
6. Pageophile DEPOSIT RECEIVED
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27. onerippinturbo2
28. shelbyvnt2
29. Chrysler GS -89
30. j4278h
31. 89TonaVa

[Vigo]

Mine is in the mail, was thinking you will get it today or tomorrow.

[acannell]

Mine is in the mail, was thinking you will get it today or tomorrow.

awesome!!

[acannell]

NEWS:

New fuel rail mount machined. Seems to fit well and functions as intended. Attaches with two 1/4-20 bolts per mount. Can use stock bolts for attaching fuel rail.

Runners received! Just need sum cuttin'

[moparzrule]

Gorgeous.

[acannell]

Thank you knownenemy, old man jones, iTurbo, and Vigo!!!

1. Vicus
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18. The Pope DEPOSIT RECEIVED
19. The Pope DEPOSIT RECEIVED
20. GLHNSLHT2 PAID IN FULL
21. byghtn
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23. Spiritman
24. nyvision
25. OmniLuvr
26. shmedley
27. onerippinturbo2
28. shelbyvnt2
29. Chrysler GS -89
30. j4278h
31. 89TonaVa

[acannell]

intake buffet!

moparzrule:your intake is a cut elbow, 2 feet of welds, and a shipping box away from being done unless I'm forgetting something