MACHINING

PORTFOLIO

CAM • CNC MACHINING • FIXTURING

Aditya Bansal | Mechanical Engineering, Purdue University

FSAE powertrain + PURPL turbopump

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PROJECT 01

FSAE — CNC-Machined Oil Pump Mount

From CAM strategy and workholding to a multi-operation aluminum part.

CAM setup and stock orientation

Finished geometry after multiple setups

Material Stock – 6061 AL

Machine – 3 Axis CNC Mill

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FSAE — Oil Pump Mount

First Operation CAM

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FSAE — Oil Pump Mount

Second Operation Goal

Part is FLIPPED over and put into fixture, secured via bolts, bolts must be avoided

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FSAE — Oil Pump Mount

Second Operation CAM

Part is FLIPPED over in fixture, secure via bolts, bolts must be avoided

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FSAE — Oil Pump Mount

Second Operation CAM Cont

Finishing passes and contours

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FSAE — Oil Pump Mount

Machining Execution

The machining sequence uses two operations, one to machine the piece out of the stock, then flipped over and dropped into fixture to finish

First Op – roughing pass, bore, slot cutter for O-ring

Part flipped and dropped into fixture with bolts

Fixture Machined to hold first operation part

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FSAE — RESULT

Finished Component & Challenges

Engineering challenges and solutions

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• Slot cutter tolerance, test cut was made on separate stock
• Bore tolerance, updating tool wear on machine was used with concentric probing
• Thin webbed geometry chatter – fixture was created to seat against webs to prevent
• Bolt collision – operation was created to use 4/5 bolts at a time, machine to surface, put 5^th bolt in and remove another , repeat

Finished component

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PROJECT 02

PURPL — Turbopump LOx Casing Post-Machining

CAM and CNC post-processing of a metal additively manufactured turbopump casing.

As-printed turbopump LOx casing

Post Machined LOx casing

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PURPL — LOx Casing

Machining Objective

Machining focuses on machined faces, bore tolerances, ports, threads

Blue – To be Machined

Pink – Final Part

Material – 316L Steel

Machine – 5 axis CNC Mill

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PURPL — LOx Casing

First Operation – Bores and Drill

Fixture Machining

Facing

Boring

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PURPL — LOx Casing

Second Operation – Ports and Threads

Port Pre machining

Port ORB Seal

Threading, repeated at multiple stepdowns

This process is repeated for all ports: 1x -24, 2x -12, 2x -8

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PURPL — LOx Casing

Machining photos

CNC operations establish flat sealing faces, concentric bores, threaded ports, and bolt patterns on the printed housing.

CNC machining under coolant

Finished flange and internal bore

-8 Thread up close

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PURPL — LOx Casing

Final Product

Key Challenges & Solutions�- Bore tolerance: update tool wear and multiple stepdowns

- Thread Tolerance: Multiple stepdowns and correct thread mill sizing

- Mounting to fixture: Used counterbored bolt holes underneath fixture to allow for nut to fit on part plange

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