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Re: Volvo G990 Grader
The recessed end portions were bent with a more sturdy fixture than used for other parts earlier in the build.
https://drive.google.com/uc?id=0B_yT...mF3TllzVjBhM1U https://drive.google.com/uc?id=0B_yT...k9LUS1ONEZaUFE https://drive.google.com/uc?id=0B_yT...zZ4ZHhsWDNtdmc https://drive.google.com/uc?id=0B_yT...k02azFZUzhpak0 https://drive.google.com/uc?id=0B_yT...HBfdlRtc3pIN3c Thanks for looking. Stefan |
Re: Volvo G990 Grader
Always fun trying to get the correct radius when bending around a mandrel like you are doing. If it's not right you have to keep turning down the mandrel diameter till the spring back is where you want the radius to be.
Sometimes when I bend 180deg bends , the mandrel needs to be maybe 1/4'' smaller diameter than my finished bend. |
Re: Volvo G990 Grader
Steve, in the figure I´ve tried to illustrate a piece of material which has sprung back after having been tightly bent around the mandrel. The next time you bend something you should note down the spring back ratio k=R/r of the material. This, in my experience, is a material constant. So thereafter you can easily calculate which D you need for the R you really want as:
D=2R/k-t where, obviously, t is the material thickness. https://drive.google.com/uc?id=0B_yT...XFGQ0tQaG4wWGs Stefan |
Re: Volvo G990 Grader
I´ve some pics from modelling the lower edge of the moldboard blade. First, a 2 mm strip had a radius formed to it and was soldered to the back of the blade.
https://drive.google.com/uc?id=0B_yT...ldaX0NaY3JfZFU https://drive.google.com/uc?id=0B_yT...0k3My1mdzQtaG8 The heat caused some unwanted bending https://drive.google.com/uc?id=0B_yT...U1QdEdPeC1BRGs Milling the forward side to replicate the recess. The strip enabled a good grip in the vice. https://drive.google.com/uc?id=0B_yT...nRscnl4YWFFUVk https://drive.google.com/uc?id=0B_yT...lU4VG9lU0FZbXc This is the first pass with the radius mill which took care of the concave radius of the S-shaped bend. There were a further two passes made to approximate the convex radius. I still have to remove (probably by grinding) the remaining material on the convex radius. https://drive.google.com/uc?id=0B_yT...DZDN0dPVlB3b0E Thanks for looking. Stefan |
Re: Volvo G990 Grader
Short update: Got the laser sinterered end pieces for the rear axle (works on blade has been put on hold). Needed a little machining, of course.
https://drive.google.com/uc?id=0B_yT...mJ2cndYQjZjdG8 https://drive.google.com/uc?id=0B_yT...DBqUVc1U0NBSTA https://drive.google.com/uc?id=0B_yT...XFFd0pQYldZYVE https://drive.google.com/uc?id=0B_yT...WU0MHlkTXRnLUU https://drive.google.com/uc?id=0B_yT...zJ4TC1YZW91dlk https://drive.google.com/uc?id=0B_yT...2hFY2hoVGtyMVk |
Re: Volvo G990 Grader
The laser sintered parts looks great. Is this Stainless steel + bronze? I am about to order some parts of that material, and have noticed it is very hard material. Is it difficult to tap threads into this material? I would guess that with smaller taps than M3-M4 there is big risk for the taps to break?
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Re: Volvo G990 Grader
Yes, it is stainless steel + bronze and it is indeed rather hard and tough. I use hard metal drill bits whenever possible. Even the HSS ones specially made for "normal" stainless wear much too fast. You are also right that it is very easy to break the smaller taps, because the torque needed is so large. Nevertheless, the smallest done so far was M1 for the screws holding the lid on the circle valve. The secret is to drill larger holes than the standard says, using high performance tapping grease and to make sure you tap straight. By the way, the tap you see in the last picture is an M3 thread former. I´m getting more and more fond of using formers since the day I managed to make 64 M1.6 threads in AISI 304 (1.4301 X5CrNi18-10) without breaking the tap (I did brake one or two drill bits, though). As you know, 304 is good for welding but hard to cut, since it cold hardens. In my experience, the stainless steel + bronze from Shapeways is even tougher than the 304.
https://drive.google.com/uc?id=0B_yT...HVwbGpmYkZCb0U |
Re: Volvo G990 Grader
Interesting way of manufactoring, Stefan. Didn't know that was possible. Hard to tell but what is the size of the valve?
/Dan |
Re: Volvo G990 Grader
:Di do think we have a master craftsman at work this is an incredible build and i can not wait to see more of your work not just of this model do have any other master pieces that you have made plz send me pics my email .s jvan320@gmail.com
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Re: Volvo G990 Grader
@Dan: The size is 15,6 mm from bottom to top of the lid. The body diameter is about 8,5 mm.
@Jack: Thanks! I´m glad you like it. More pics will be coming. /Stefan |
Volvo G990 Grader in 1:8
Finished the end pieces for the rear axle.
https://drive.google.com/uc?id=0B_yT...1dRbHoxR3FLMk0 https://drive.google.com/uc?id=0B_yT...VdIWVZLZDFHQ00 In it goes the planet gears carrier/output shaft from a cordless screwdriver. https://drive.google.com/uc?id=0B_yT...01pX0d6UkpocU0 https://drive.google.com/uc?id=0B_yT...2I2aTFvcTllQW8 https://drive.google.com/uc?id=0B_yT...FpUOVJBM2tkNE0 Thanks for watching. Stefan |
Re: Volvo G990 Grader
Very nice, Stefan
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Re: Volvo G990 Grader
Those planetaries look great! Well, everything else does, too.
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Re: Volvo G990 Grader
Great job, this will be one **** of a model when done!
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Re: Volvo G990 Grader
Great work as usual Stefan
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Re: Volvo G990 Grader
WOW Another work of art Stefan,
Thanks for keeping us involved in your build. :D Greg |
Re: Volvo G990 Grader
Thank you guys for those words of appreciation.
Havent´t done much on the grader lately, but anyway I got the so called "anchorage" for the lift cylinders from Shapeways and started some machining. https://drive.google.com/uc?id=0B_yT...k9KYTY1RkI4czg https://drive.google.com/uc?id=0B_yT...TBQZlp0c2NxNm8 https://drive.google.com/uc?id=0B_yT...VRtUzF3ck1BUEU |
Re: Volvo G990 Grader
Stefan, can you tell me some words about these printed steel parts? Are comparable as hard/strong than a traditional molded steel part? (I would like to make my machine's axle housing this way, but it needs to be strong enough)
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Re: Volvo G990 Grader
For hardness/strength reasons I wouldn´t hesitate at all making an axle housing from it. Maybe from a price and machining points of view. It´s actually very tough. Drilling is as difficult as for normal stainless steel, if not worse. You´d better use high quality carbide grade tools.
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Re: Volvo G990 Grader
Thanks for the tips.
I forget to mention that i'm amazed by each step of you progress. Very nice. really. |
Re: Volvo G990 Grader
Recently this was delivered from the foundry (500 grams per piece):
https://drive.google.com/uc?id=0B_yT...zRSUGRGNlJyMlE Was I :) ? No, rather :( and :mad: ! Why? Have another look! /Stefan |
Re: Volvo G990 Grader
Nice parts, I guess one is made the wrong way?
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Re: Volvo G990 Grader
Quote:
What are the pieces for? Incredible work you're doing here Stefan using many methods to make parts as exact as possible. :eek: :cool: |
Re: Volvo G990 Grader
Tack and thanks, Kalle and Joe!
The pieces are the arms for the lift cylinders, you can see one behind the cylinder in my first posting of 03-01-2016. Yeah, I ordered two each of the right and left arms but got three right arms and one left. So, one could be really funny here and say that they didn't get it right although they tried hard to make everything right :D And one right that is left will be returned :D:D so hopefully I'll have the right one, i.e. another left arm, soon, very soon, so consider this an arms race :lol: Stefan |
Re: Volvo G990 Grader
Great play on words Stefan :D... generally, how long does it take from design to finish piece for these type of parts?
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Re: Volvo G990 Grader
Well, Joe, to start with the summary that would be almost 20 hours of my own (in-? :o)effective time for each piece and, theoretically, if I hurried every step as far as the circumstances allow it, it could be done in, say, 4 to 7 weeks.
In detail I can see from my notes that I spent 13 hours spread out over a fortnight turning my documentation of the original blade lift arms into CAD drawings. Then the 3D printing shop apparently printed the mould patterns within 24 hours of receiving the CAD file. After that I had to manually adjust the patterns, because some bevels and free form surfaces had been too complex to model with my CAD program. Additionally I had to fill and sand the surface, since the 3D print layers were too coarse. I guess that took at least 3 hours for each pattern. The foundry sent me the castings about 3 weeks after ordering. I suppose that could go faster if you are a well known customer. Now I´ll probably need another 2 hours machining per casting and I just noted that there are some surfaces in need of filling due to shrinkage - add another 2 hours. Also add some overhead for contacting the service provider and mailing things. Now, Joe, it´s time to give more meaning to the word "theoretically" used above. As you may have come to understand by now, I don't feel much urge to hurry things, and in fact the first session of drawing these parts took place as early as in December, 2007. Cheers! Stefan |
Re: Volvo G990 Grader
Amazing work done Stefan. I do so like the casting technic with part numbers included. What a level of details!
Dan |
Re: Volvo G990 Grader
I love the planetary gear sets! Those should last awhile.
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Re: Volvo G990 Grader
Hej Dan. Thanks! See you in three weeks?
@"thetractorfan": Well, there are some serious doubts about that due to the high weight of the model. Time will tell. Stefan |
Re: Volvo G990 Grader
I congratulate you Stefan on your dedication to get 'er right... I sincerely hope you live long enough get 'er done! :D
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Re: Volvo G990 Grader
Yeah, thanks Joe, that thought has crossed my mind, too ...and I haven´t even started making the tires... :(
Stefan |
Re: Volvo G990 Grader
Stefan I am Blown away over you're Grader Build......can't find superlative enough !!! Did you look at Coopers Tire-making. They are super nice. I saw them in person @ Cabin Fever. By the way i want a grader badly :D
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Re: Volvo G990 Grader
Thanks Bo. Haven´t heard of Coopers Tire before so thanks for the tip but if they make scale tires they seem rather quiet about it and I haven´t been able to find anything useful on the net.
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Re: Volvo G990 Grader
Ooh !!! Sorry I was thinking of Our fabulous Cooper on the forum. http://www.rctruckandconstruction.co...t=9048&page=48
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Re: Volvo G990 Grader
tire building starts on post 966. before that its just 12 y/o kids having fun
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Re: Volvo G990 Grader
Ha, ha! :o Thanks for clarifying that before I contacted the Cooper Tire & Rubber Company :p
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Re: Volvo G990 Grader
Lol!! Cooper tire!!:). Stefan, I got most of my info from members on this forum. The pages Bo is talking about will explain better once you read through the b.s. Conversations. :). I looked far and wide for a tire to suit my build and just couldn't find what I wanted, so I made them. Pretty easy to do. Hard part is making the first one or the pattern tire. If you have the ability, and I'm sure you do, find a pattern that is scale appearance and uni-directional. You'll have one good side and a not so perfect side. If I did it over I would have spent more time on the pattern/blank tire because the silicone does transfer every small detail/imperfection. Initially it's a little costly but you get exactly what you want. My tires were say 8" tall and after I pulled them from mold they shrink about 1/4" in height, about 1/16" in diameter. I made two piece rims to act as the beadlock to prevent slippage. If you got any questions I've been following your build and will try and answer whatever I can. Your build is pretty awesome!!!!
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Re: Volvo G990 Grader
Yeah, the forum is great. Always someone with a good idea if you get stuck. Cooper, your tires look awesome! You have come far in this hobby in just some 3 years. I sure will review your tire build if I have to mold my tires myself. I´m also considering pneumatic tires. A pal of mine did it for his 1:12 models and it improves running a lot and looks excellent. It involves a lot of extra work but especially for a grader it might well be worth it. The pal has 150+ videos on youtube and I spent only a couple of minutes finding an example of them tires squatting, so there´s probably some even better example:
https://www.youtube.com/watch?v=5yXIwv6qu5Q On his dumper you see it all the time if you look carefully, but particularly at, for example, 1:00 and 3:40: https://www.youtube.com/watch?v=rb2oWCIRtsg Stefan |
Re: Volvo G990 Grader
Thank you for those videos. Love his machines!! Built to be run hard and he puts them to hard work. I'll be spending the next couple days watching those videos!!! I did think about making the tires air but I just didn't have the ambition to go that way. That adds another level of skill and scale!! Some day I may be there:). Thanks!!
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