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Tech. Advice: Series 'B' / 'C' 500cc/1000cc Bikes
New ESA Design
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<blockquote data-quote="oexing" data-source="post: 89509" data-attributes="member: 1493"><p>Well, the "male" side has three hills/cams with exact 12 mm dia., like BMW, that can easily be milled on a conventional CNC mill. You could do 1/2 " diameters as well if you prefer imperial sizes. These 12 mm shapes are cylindrical, no tapers or whatever. The trick is to use just that diameter in form of a 12 mm end mill for milling the female side. I let another DRO counter calculate positions for a circular hole pattern with steps about half a mm apart, I think, could look up my sketches. So basically the big valleys were sections of circles or radii , but you cannot machine that shape easily, you have to merge each step by positioning the cutter in , say, x-bedway plus "fake" y-position by turning the dividing head a fraction of a degree. The end mill will stay in the zero y position all time, only the x-axis gets new coordinates. I must confess most of the details I do not remember easily, that was half a year ago. But in the photo in the paper file there must be the x-positions and the corresponding degrees for the dividing head dialled in by reading the small DRO on the mill wired to the rotary encoder of the dividing head. I don´t know if I can find words to pass the idea but basically you have to simulate the positioning exactly like the ESA does on the mainshaft when it lifts and rotates under torque from the chain drive: The male partner does a few degrees and gets lifted by the female shape a fraction of a mm , the male half does a few degrees more, gets lifted a little bit more and so on, in the end the contact with the female shape reaches a lot steeper gradient and you get a very progressive damping effect so the assembly does not need to rely on blocked springs at max. torque. Maybe a few more pictures show the idea better. Anyway, in the frontal view of the modified ESA you can see that the female valleys have no parallel sides at all, but my theories were confirmed with the very first try, the alu patterns, and checked with a little bearing blue. The progressive action from the new cams can be tested by finger feel, just that I do not know the person and address I could send the alu test set . </p><p></p><p> Vic</p><p></p><p>[ATTACH=full]18425[/ATTACH]</p><p></p><p></p><p>[ATTACH=full]18426[/ATTACH]</p><p></p><p></p><p>[ATTACH=full]18428[/ATTACH]</p></blockquote><p></p>
[QUOTE="oexing, post: 89509, member: 1493"] Well, the "male" side has three hills/cams with exact 12 mm dia., like BMW, that can easily be milled on a conventional CNC mill. You could do 1/2 " diameters as well if you prefer imperial sizes. These 12 mm shapes are cylindrical, no tapers or whatever. The trick is to use just that diameter in form of a 12 mm end mill for milling the female side. I let another DRO counter calculate positions for a circular hole pattern with steps about half a mm apart, I think, could look up my sketches. So basically the big valleys were sections of circles or radii , but you cannot machine that shape easily, you have to merge each step by positioning the cutter in , say, x-bedway plus "fake" y-position by turning the dividing head a fraction of a degree. The end mill will stay in the zero y position all time, only the x-axis gets new coordinates. I must confess most of the details I do not remember easily, that was half a year ago. But in the photo in the paper file there must be the x-positions and the corresponding degrees for the dividing head dialled in by reading the small DRO on the mill wired to the rotary encoder of the dividing head. I don´t know if I can find words to pass the idea but basically you have to simulate the positioning exactly like the ESA does on the mainshaft when it lifts and rotates under torque from the chain drive: The male partner does a few degrees and gets lifted by the female shape a fraction of a mm , the male half does a few degrees more, gets lifted a little bit more and so on, in the end the contact with the female shape reaches a lot steeper gradient and you get a very progressive damping effect so the assembly does not need to rely on blocked springs at max. torque. Maybe a few more pictures show the idea better. Anyway, in the frontal view of the modified ESA you can see that the female valleys have no parallel sides at all, but my theories were confirmed with the very first try, the alu patterns, and checked with a little bearing blue. The progressive action from the new cams can be tested by finger feel, just that I do not know the person and address I could send the alu test set . Vic [ATTACH=full]18425[/ATTACH] [ATTACH=full]18426[/ATTACH] [ATTACH=full]18428[/ATTACH] [/QUOTE]
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Tech. Advice: Series 'B' / 'C' 500cc/1000cc Bikes
New ESA Design
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