Hyena wrote:Or is it a very elaborate backyard set up ?
Danny Mayes wrote:Hey Todd,
lol, Aj might be a few things closet but i don't think friction drive is one of them hehe.
Interesting to find out more about the frame though, cheers for that.
Spun out it was an electric! cool.
Well, had mixed results with the casting. This was the first time I cast aluminum and the first time i have done lost foam. Progress definitely, weather i can use it or not is another matter.
It was a long day yesterday. The furnace got some moisture in it so we took things real slow. We started at 9 am and finished 15 hrs later at 12am. It was a productive day however. We poured a total of 40kg of silicone bronze and 8kg of Aluminum. Our first pour was at 5pm by the time we sorted out the moisture issues but we were turning around 10kg of bronze every 75 min after that... same volume of ally was about 30
By now it should be evident what i am doing with the rear drive. The casting is a 131 tooth T10 pulley. It is the same diameter as a 20" rim. It will be cleaned up and fixed to the machined side wall of the rim. like i said, it's a bit kinky but i am achieving 11 to 1 reduction in a single stage. I think it should look cleaner than a big pulley mounted in the tradition manner. In this application it should be good for around 12kW.
You will see in the pic above another small mold next to the big mold of the pulley. this is a tradition pattern, not lost foam. I was a little ambitious ramming up this pattern in that mini little molding box and as we poured it, the side of it came away. So, i am gonna withhold details on that one for now but I will update with pics over the next 2 weeks when i get a result worth sharing.
With the pulley, i don't think it shrunk quite as much as 0.11% which i factored for. I will only know when i clean it up though. Once cleaned up, i will measure it and probably cast another one with my correct and now know contraction number. Also i think i might modify the tooth profile to accommodate me some room for minor diametrical errors.
So, not a complete result yet but half way there definitely!
Thud wrote:Hey Danny,
I had no idea you were doing investment stuff at that level in the back yard. We have the brain power here to design & build a nice induction furnace that would let us cast some exotics in a controlled atmosphere.......would you like to melt a 10#s of stainless in 15 minutes?
I would like to see your burn out oven & share some recipies for investment is your doing home brew....I have been meaning to put together an ellectric oven for the controlled temps required for a proper burn out of investments.
as for lost foam....too easy. I would have had a few more runners to help feed metal into the part as fast as possible (but you got it!)If your in loose sand venting is pointless, in green sand you will see benifits. Also any time you can fill from the bottom up the more consistant your results will be.
I havn't done much lately but most of my casting stuff was for self indulgent sculpture & card protectors for my poker tournament friends. heres a couple weak pics.
a "tree" of brass card protectors
& cast aluminum rings just for fun.
You prolly have these links but i will post a few for the tourests around these threads.
Thud wrote:as for lost foam....too easy. I would have had a few more runners to help feed metal into the part as fast as possible.
LI-ghtcycle wrote:looked to me like he had at least one that didn't fill out well from the pics.
Thud wrote:Also any time you can fill from the bottom up the more consistant your results will be.
LI-ghtcycle wrote:hrm...I do believe this is where I say "I told you so" Danny boi
Umm YES!Thud wrote:We have the brain power here to design & build a nice induction furnace that would let us cast some exotics in a controlled atmosphere.......would you like to melt a 10#s of stainless in 15 minutes?
LI-ghtcycle wrote:Please also show more pics of your foundry set-up if you can, I can only imagine how much power/gas (I'm thinking it must be a natural gas fired furnace?) it takes to melt the metal?
LI-ghtcycle wrote:I would imagine the foam would tend to "gas off" a lot when it burns leaving some bubbles in the casting?
I have talked to Tim a few times...Hes a young genius to be sure. loves his ellectronics & I miss his abrasive wit on the old metal forum. (most hated kid on the internet LOL) I knew he was planning to make those as "kits" but he went off to colledge & i haven't looked him up for a while.
Thud wrote:I been using an old furnace as a kiln for my homeade crucibles & investment burn out....the big issue is temp controll up or down..Just too fast in either direction..also had thoughts of fabbing a down draft kiln just for the purpous...too many projects too little time you know the story.
Toorbough ULL-Zeveigh wrote:scratching my head here, that's a strange nickname for a girl.
i know, gusalina.
does she have a brother name sue?
Danny Mayes wrote:Can anyone recommend a good free ware program for compressing and editing video
Danny Mayes wrote:Also Li-ghtcycle, you suggested putting a riser in as per your drawing, what perpose does that serve? I did have a vent that was about 5mm diameter to ensure i got full fill...
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