Hoobz904. How aluminium forged pistons are made. Narrated using satire.

[pixOH]

LMAO

[rbolenderiii]

Very cool!

[bassdownlow007]

can anyone tell me which is the best material to make piston and why? thanks!!

[villagekid18]

What forging process is this called please?



[jasonmhall1972]

Hi I have forged pistons for sixteen years in uk for omega our pistons are simply the best in the world ps those billets are way to hot! Also the cutting of the billets would leave saw marks then they would be forced into the forging...... lazy

[mikerjuk]

Regular pistons are cast, i.e. the aluminium alloy is melted and poured into a mould. They are cheaper to make, and can produce more complex and often lighter pistons but cast materials tend to be brittle, so a failure (e.g. through detonation) will cause a piston to break up. A forged piston is stronger and more ductile so more suited to high power applications.

[Hoobz01]

@mikerjuk Thanks for sharing the info Mike. 

[Freakawn]

@mikerjuk A new way to create parts called "Additive processing" (new to industry, old to humanity) works with very small amounts of aluminum alloy, slowing build it up into the part needed. This allows of extremely complex designs while keeping the structural integrity of the product. Also, this allows for less material to be wasted, as you are building up and not breaking down a block of material.

[mikerjuk]

@Freakawn I've heard of additive manufacturing using polymers and sintered metals (fused with lasers), but I wasn't aware of any processes that could approach the material qualities of forged silicon/aluminium alloys? That would certainly open up a huge range of applications.

[marek0086]

@mikerjuk~ no your wrong!.... a forged piston can be made lighter than a cast of the same strength. 

[mikerjuk]

@marek0086 The word you seek is "you're", a contraction of "you are". And I'm not wrong, read my original post again, carefully.

[EasternEb58]

what exacally is the diffrence between a forged piston and a regular one

[rofLopolous]

Fuck i love this vid, purely cos of the commentary :D

[tyIerz06]

What is the forging pressor made out of, iron?

[2strokeaxe]

Fucking unions, good for nothing these days.

[441rider]

:o) nice. Ti pistons, I tried Ti pushrods with similar challenges except it machined my BSA!

[turneynicholas]

how much is a set of sbc pistons from your company

[mitkoman]

THIS DUMB ASS EDITED THE VIDEO AND DIDNT STOP TALKING ANNOYING CRAP!!

[shadetreeforge]

Hi Hoobz01 The funny thing about this is my name actually is Frank, and no I'm not offended :) as for the guy in the video I haven't seen him in years, and I won't tell that u made fun of him... the machine he is running is 2000 ton (forging force) forge press mfg by Ajax. the building is so short in height that when the company bought the building they actually had to sink the machine 1 foot lower into the floor than normal

[shadetreeforge]

Hi, I used to work for this company for 16-1/2 yrs and help develop many of the forging process improvements! after the company sold out to Dover Corp. in 1999 about 3 or was it 4 yrs ago they decided that I wasn't needed any more... BTW I'm not the guy in the video, he was one of my fellow co-workers.

[Hoobz01]

@shadetreeforge Thanks for the info shaded. Pity they let you go though. So you weren't Frank or Tiny in this vid? I'm amazed that someone who actually worked there has seen this. It shows how small the world really is. Please don't tell Tiny I made some fun of him, his hands are massive, I don't want them around my throat.

[andersenchong]

Thanks for the video! Now I know, how the forged piston made ;-)

[datsun16004me]

i would sack all those guys/gals at fault

[qwertyI234]

The part about the titanium pistons was funny.

[bikerjazz1]

nice video, is that what u do for a living? what bone did u break in your wrist ? i broke the scaphoid , hopfully get the 2nd cast off on the 22nd, been 10 weeks, putting the bike together today , did the desmog and re jetted cut exhaust , cant wait to see how she works, will make sum more vids soon i hope, Jazz

[Hoobz01]

Thanks bikerjazz. I'm a carpenter, not a machinist. As above, I did the vid out of boredom. I have a distal radial fracture, which means my main arm bone is broken at my wrist. A few people thought it might be my scaphoid when I did it because that's a very common dirt bike crash break isn't it. I've had the cast on for 3 weeks with another 3 to go. I'll check out that desmog clip as soon as youtube vids work for me again. Dave.

[MotoDareDevil]

sweet video, and i know what your going through with your wrist. I broke and dislocated it riding my mountain bike last 2 months ago, and just got my cast of last week. Went through 3 cast. Two full arm and one half arm. Now im bike on my motorbike and mountain bike. And i would reconmend a wrist brace for the moto riding when you get back out there. I got a 661 Pro Wrist Guard. There great, $30 bucks each.

Cheers Andrew

[ScaryJudgeofCaracter]

Bloody unreal Hoobz! Love Frank and Tiny, the lubricant not hitting the cutting face of the tool and the union stepping in to save the boys jobs. There is a lot to be said for compulsory unionism.. hahaha

[Hoobz01]

Hahaha.

Yeah. I couldn't help but have a bit of a dig at unions.

Also remember that titanium isn't too good at forging either. hahaha

[anthonyparisotto]

Whens the two stroke version coming mate?

[Hoobz01]

I'll have to go into the really dusty part of the archives for that one :P

[robocrf67]

your a nut !!!!!!

thanks hoobz as i missed it yesterday bloody work

[Hoobz01]

Hahaha.

You're welcome rowbow :O

[vmxrm85]

that is very cool!

[Hoobz01]

Geez VMX you're quick. haha. I didn't think it was public yet.

I ripped off the video footage and just added my own dribble.

Still waiting for the HD version to be processed.

Glad you like it.

[vmxrm85]

yeah i always wondered how they were made

[sumayo2]

Cool video Hoobz, but...... at 3 mins 11 secs, you said the bit is sloppy... it is actually a circlip grooving tool, fly cutting a circlip groove or something similar.... fwiw.... Done heaps of machining, could do it in me sleep.... fwiw

[Hoobz01]

I should point out that the vid was a bit of a joke. I'll change the title. I know the machining tool was designed to move around like that.

[Hoobz01]

I changed the title and description of the vid sumayo just in case someone else believes we tried to forge titanium pistons too or something. hahahaa. I'm glad you liked the vid too.

The actual footage is from the show 'How it's made' if you want to watch the proper version. It's pretty good to watch.