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Product category: Software, off-line programming, CAM, for metal cutting machine tools
News Release from: Delcam | Subject: CAD/CAM software
Edited by the Manufacturingtalk Editorial Team on 15 November 2007

Machining software speeds cylinder heads

At the UK's Autosport Engineering 2008 event, a CAD/CAM provider will tell how a set of cylinder head ports can be machined, tested and installed, from a prototype, within one to two days.

At the UK's Autosport Engineering exhibition, to be held at the NEC, Birmingham, January 10-11 2008, CAD/CAM developer Delcam will be presenting its latest products and disc ussing autosport CAD/CAM applications

The company said that while its software is being used adopted by manufacturers of engines and other components, the company is best known in the industry afor its PowerINSPECT inspection software.

The software is used by the FIA and NASCAR to check vehicle conformity.

Delcam told manufacturingtalk.com that the company's first major success with engine manufacturers came in 2004 when its PowerMILL CAM system was chosen by Zytek Engineering.

Zytek is one of the world's leading specialists in automotive control systems, race engine design and development, powertrain development and hybrid-electric vehicles, for the manufacture of all engines for the A1 Grand Prix series.

Since then, Delcam and Zytek have cooperated to develop novel machining strategies for motorsport engine manufacture.

In particular, strategies were developed for the finish machining of inlet and exhaust ports.

The results included reductions in machining times of up to 60%, together with better quality and consistency.

A more recent success was at the US engine builder, Wegner Motorsports.

Wegner engines have competed in nearly every NASCAR division, including winning multiple championships in the BUSCH Grand National series.

Again, the main benefit of the software is in CNC cylinder head porting, said Delcam.

Machining software PowerMILL allows an entire set of cylinder head ports to be produced from a hand-crafted original, machined, tested and installed into an engine, within one to two days.

Casey Wegner, Carl's son and head of the CNC department, said: "Previously, it would take us between 20 and 26h to machine the ports.

Now, we can complete a head in about 45 min.

Plus, people in the industry are amazed at how smooth the walls of our ports are".

* Machining non-standard components - in 2006, Coventry-based Visioneering used PowerMILL CAM and PowerSHAPE CAD software to produce the majority of the components, apart from the powertrain, in the record-breaking JCB 'Dieselmax' car.

The unique demands of the project meant that hardly any standard components could be used.

Even apparently routine items, such as hinges and catches, had to be machined from solid to ensure that they would give the high level of quality required, said Delcam.

PowerSHAPE and PowerMILL were used to design and machine the tooling for the body and the underfloor in carbon-fibre reinforced composites.

Extremely advanced flow analysis (CFD) methods were used to optimise the shape of the body so it was essential that the tooling was able to reproduce this form exactly, said Delcam.

According to operations manager, Adrian Coppin, the most impressive components were the two engine covers.

These were machined from solid using programs generated in PowerMILL.

He said: "For machining accuracy, these were the best parts we have ever produced. Request a free brochure from Delcam ...

The surface finish that we achieved was remarkable - no hand finishing was required at all.".

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