5 axis cnc Porsche head porting

[ydna2]

Interesting about the feedrates....I can't get my non-HSM vf2 to exceed F700-F800 in G93 without the rotaries hesitating....maybe someday we'll get HSM and be happy. hah

[cipressnery2009]

THIS MACHINE IS UNA CHULADA

[princeigorash]

Hello.Can you tell me how did you tooked the original port geometry? Is there any scanning device?

[rwolcott23]

@princeigorash I sent the head out to a company that scanned the geometry for me. This was in the form of points and I created the final surfaces in ProE.

[LowRoller420]

Wow, a Haas that is running. You don't see that everyday.

[rwolcott23]

Unfortunately, I have to agree. Both of my Haas machines have been very problematic.

[dirty1douglas]

haas vfs vf3 cincinatti horiz. cin. 5 axis, pays to be a machinist

[Valtomotive]

i run a HAAS VF2,VF3,VF5 and VF9 nice video

[IROC4LIFE]

Nice Machine, I run a new VF3 with the same 5 axis setup at work, pretty slick, can't wait to do some after hour's cylinder heads for myself.

Also, you really have the tool changes cranked up, the local HAAS dealer sets them up much slower due to the issues with tossing tools, and spindle taper damage.

Cheers.

[benwara]

actually i'm pretty sure that he has the high speed ATC option.

[trishprasbud]

yup you were right, the HAAS machine with Side Mount Tool Change about 2.8 second tool to tool.

because, during atc the Z axis will move up and down ( it's not fixed in Z axis tool change position) and also design for the arm is shorten then the other machine.

[newcomer9747]

why does the workpiece has to be rotated while machined?

[rwolcott23]

It has to be rotated because the geometry is so convoluted it would take several setups to remove all the material. It could be done with standard 3-axis machining but there would be 5-6 fixtures required and each would be expensive to produce.

[rwolcott23]

Accidentally removed your latest comment, sorry. The port is larger in the mid section than it is at the valve seat or manifold interface. It also makes a 65 degree turn. A .500" lollypop cutter would only be able to machine the undercut for 30% of the depth, maybe. I have heard of people cutting these with 4-axis but never 3-axis. It could be done but the fixturing would be elaborate.

[rwolcott23]

The video doesn't show it, but each port is machined from both directions as well. 3 axis machines can be converted to 5 axis which is exactly what I did. I needed to uprade the control for 5-axis, buy a post processor, upgrade Mastercam, and buy the trunnion. I am still a newbie and true 5-axis programming is very involved and has a steep learning curve. 3+2 is very easy and convenient as well.

[newcomer9747]

Ah I see... So the section has an undercut which could not be practically possible to machine on a 3axis.

How much'd you spent on the conversion and what tolerance and surface finish can be achieved with a converted 3 to 5?

[rwolcott23]

The conversion with all that I mentioned above was ~$40k. I am very impressed with the tolerance and surface finish that this can produce though with any surfacing it depends on how long you want to wait :-) Fixturing becomes very important because the origin (G54) is ALWAYS set where the trunnion's rotational axis intersect.

[ydna2]

Nice short demo, keep it up!

[chikotube]

bit-loading was scary

[rwolcott23]

Yes, due to the limited spindle Z clearance the table rapids to a set location before changing tools. The tool swings about 1.5" from the trunnion body.