Part of the problem is extreme flexibility of the lathe.
Even with a bigger lathe, I have had built-up edge, which makes the lathe "slam" and cuts a gouge in the metal.
If I had a lathe that used those 3/4" tungsten triangular tips and a huge amount of torque, then things would be a bit...
Got the inner dome part of the cylinder head done.
I used a square tip tool ,with front and side rake, then angled the tool holder back against the direction of cut.
I think about 5 thou per cut.
Finished with a rotary round-nosed mill/burr/file in a drill while spinning the head in the lathe...
1)I did find a video illustrating the brute force approach. this looked like a triangular tungsten tip about 3/4" wide,
and about an 8 inch chuck.
My chuck is 2 inch...
2) I did use the boring relief on the outward edge.
I don't need it going the other way.
3) I am using about a 5mm square...
I am making a small engine cylinder head on a "Micro" lathe.
I am working of a domed recess in the main chamber, which is the squish area of a two-stroke.
I found that if I come straight in from the front side, then cut towards the centre,
I need zero top rake, a fair bit of front rake, and a...
I will look for more dividers.
Are these the compass type with a screw adjuster in the middle?
That slotted bush system looks interesting.
I find I also want some hardened steel scrapers. They can be handy.
I re-chucked a cylinder head blank, and could not get it to centre properly. I need a...
There is one called a Big Gator Metric V-Drill guide for woodwork, $56 nz. I could use one of those.
I could also make a plate and insert the full range of bushes in it. Generally bushes are not conveniently shaped to go into a piece of 3-4mm plate.
There is no need for it to be 1/2" thick...
I can't find these on Google.
What are they sold as?
I saw one once on line.
they have many hole of different sizes in a hardened steel plate.
hole sizes 2mm to 10mm
This is handy for making small engine parts.
The objective is to simply clamp the plate in place and drill through a hole.
I have suspended this as a project for now. It might make a better case with fuel cell technology, but this seems to be immature and not widely accepted. For instance no work on hydrogen production at the point of sale in being reported widely, or on sustainable central production of liquid...
I had second thoughts about this: thrust bearings are not supposed to be used for offset and angular loads. Possibly roller-type thrust bearings can be used to retain the rotor, with roller bearings to take the bending loads. inner races can be located with tubular spacers. A tubular outer tower...
For now, there is no pressing business case to continue, and this approach is a bit expensive to obtain a hobby aircraft.
The version paralleling Robinson R44 performance specs seems to be feasible using petrol-electric drive. A good weight, rotor area, power, range match.
I have no desire to...
The Quadcopter design, without the cyclic pitch control, seems to develop massive bending torques at the rotor head mount, when cruising at speed. (5m rotor) I looked at some helicopter shaft-rotor join detail drawings on Pinterest, and they seem much lighter built.
Has anyone seen drawings for...
Possibly carry passengers (non-paying?) + pilot. -eventual goal.
Extensive ground testing, tethered flight, and remote-control flight tests, are planned.
Possible one-off certification as experimental. I will check regulations, inspection, and testing requirements.
Use of uncertified...
Continued:
It looks like this type of gearbox is non-standard.
I have found an electric motor that runs at 4000 rpm with the correct power output,
so I need to have a custom box made up at 4:1, and inline epicyclic.
I could fit the output shaft of the standard 2.5 (say) offset box to the gears...
I have found a supplier for specialist electric motors for aircraft. (MGM-Compro). Possibly one of theirs can be used as a generator.
Waiting on a reply.
Now to find aviation-rated reduction boxes with a prop-mount output shaft.
I have put this on the rotorcraft forum.
Aviation-rated reduction gearboxes 10:1 55 kw prop mounting.
I need to find an appropriate company that does this. I found a good one for motors and controllers, but they don't do gearmotors.
I suspect industrial gearbox makers don't want their products used for this.
There is about 6 kN pull...
Apparently the tesla model 3 motor is 211 kw peak, 45 kw continuous. I am not sure if it is water cooled? I will check.
It is permanent-magnet synchronous, and probably worth a look-see for sizing and general tech.
211 kw continuous I could work with, just to get going. This could be reworked as...
I have some queries out to rewinders, thanks.
The main problem is 4 x the heat, and 1000-odd amps is a bit high.
We need to go to 1000 v plus, with associated air gaps etc, plus extra cooling.
We need a motor designer to lay it out, and see what can be done with any standard parts.
I then need...
Indeed I think this is custom build territory. Now to find someone who will build one-offs, at normal hourly rates.
A lot of the components should be common from standard motors/alternators. It likely needs to be water-cooled.
In New Zealand, it is hard to find someone who actually advertises...
Hello- I am looking for 8000 rpm and 400 kw, I suppose high frequency, about 600 V.
Anything between 150 and 400 kw could be suitable- It is for a high-speed genset for a hybrid aircraft-basically a giant quadcopter
Running at full power would result in a 200 mph breeze - a little dangerous to...
This question seems to be forbidden on most other forums.
I cannot get any sense out of Google. please help!
High speed, high power alternators don't seem to come up.
I don't know why, they are used on micro-turbine gen sets, so someone must make them???
