Rotax 2-Stroke Go-Cart Engine Cylinder Head Cap

This part was an interesting challenge since the goal was to do all the ‘turning’ and milling on a 5-axis milling machine.  There were several critical concentricity and circularity callouts which posed a challenge as well as the deep cooling fins with 0 deg draft.


Also note the complex water ports that can only be machined using simultaneous machining using a burr or lollipop cutter.  These features were programed using CAMplete Port.

Additional Info

  • Material: Aluminium 6061
  • CAM Software:: CAMplete Port, Delcam Powermill, CAMplete TruePath
  • Machine Tool: GFAC Mikron HSM400U
  • Tool Holders: Rego-Fix PoweRgrip
  • Cutting Tools: Emuge Franken, Sowa
  • Setups: 2
  • Work Holding: System 3R MacroHP
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