On Thu, 15 Mar 2012 13:43:35 -0500, Tim Wescott
wrote:

On Thu, 15 Mar 2012 12:10:40 -0600, Pete C. wrote:

Tim Wescott wrote:

On Thu, 15 Mar 2012 10:20:42 -0600, Pete C. wrote:

Tim Wescott wrote:

How would one make nice sharp-cornered, clean-sided (I'm not sure of
the surface finish, but mirror-bright would be nice) square holes,
about 0.1" on the sides, off center from the axis of the bar (so not
square to the bar surface), in a round steel bar about 0.75" in
diameter?

Alternately, how might one make those same holes in a cylinder
machined out of that same bar, with a wall thickness of about 0.06",
without distorting the cylinder by more than a couple of thousandths
(I am assuming that one would have to do some post-operations to
clean up the cylinder after making the holes, unless one hand-filed
them).

This is a thought experiment for making cylinder liners for 2-stroke
engines of about 0.2 in^3 displacement; the holes would be the
transfer ports, and the cylinder liners need to have their diameter
controlled to about 0.001" on the outside and less than that on the
inside for proper sealing (or if not controlled, then at least
matched to the crankcase that they slide into, and the piston that
slides in them).

--
My liberal friends think I'm a conservative kook. My conservative
friends think I'm a liberal kook. Why am I not happy that they have
found common ground?

Tim Wescott, Communications, Control, Circuits & Software
http://www.wescottdesign.com

Wouldn't this normally be just a milled slot? Square on the top and
bottom (relative to the piston stroke) with the edges running off the
cylinder leaving square "knife edges" at the ends? At 0.1" perhaps a
pass with a slotting saw rather than a super small and delicate end
mill.

Schnuerle ported engines want transfer ports that direct the gas toward
the cylinder wall away from the exhaust port -- that tends do a good
job of blowing out mostly spent combustion products, while retaining
the most possible unburned fuel/air mix. More power, better fuel
efficiency, cleaner burn -- what's not to like? (Except for the
difficulty in machining, of course).

--
My liberal friends think I'm a conservative kook. My conservative
friends think I'm a liberal kook. Why am I not happy that they have
found common ground?

Tim Wescott, Communications, Control, Circuits & Software
http://www.wescottdesign.com

I'm having a little difficulty picturing exactly what you're trying to
do. Perhaps drill and broach? You can make your own broach a bit more
easily than the ECM and EDM lines of thought. Come to think of it,
perhaps rotary broaching might do what you need.

http://en.wikipedia.org/wiki/Schnuerle_porting. See the picture in the
upper right. Now imagine that instead of having two transfer ports
feeding gas to the cylinder, there's four; the two shown, plus two more
that are rotated more away from the exhaust. Then, if that's not enough,
a fifth "boost" port directly opposite the exhaust, and pointing toward
the top of the cylinder.

The whole idea is that the transfer gas hits the pocket at the cylinder/
piston junction, then rises up the back of the cylinder in a fairly
unified mass; because this mass is increasing in volume, it naturally
pushes the spent gas out the exhaust port. Cross-flow scavenging (the
kind where there's a fence on the piston) tends to mix the gases a lot
more.

There's a lot of hand-waving explanation for why it works, but the bottom
line is that it works better than cross-flow scavenging!

Shoot. You're five-porting. 1960 go-carting, here we come! g

--
Ed Huntress