CNC engine crank case design

CNC engine crank/case design

PM Tuning, a leading seller of classic scooters and performance parts, approached me to reverse engineer a CNC crankcase and cover for Piaggio/Gilera 2-stroke scooters. The goal was to create a high-end product tailored for racing enthusiasts and tuning seekers. This involved reengineering a standard engine, redesigning it in 3D CAD, and modifying the design to produce a unique offering.

Project Overview

Challenges and Constraints

Machining Constraints: Ensuring the design could be produced using traditional CNC machining operations from a cast billet of aluminium, optimizing to minimize machining time and costs.
Accuracy and Fit: The design needed to be precise, allowing for seamless integration of auxiliary parts such as the reed valve, bearings, and cylinder.
Design Optimization: Balancing the need for a high-performance design with the constraints of CNC machining, ensuring that the product was both functional and manufacturable.

Solution Approach

Disassembled and analyzed a standard Piaggio/Gilera engine to understand its dimensions, components, and assembly.

Created detailed sketches and measurements of the original engine components to serve as a basis for redesign.

Developed initial 3D CAD models based on the reverse-engineered data.

Modified the design to enhance performance and cater to the needs of racing enthusiasts while considering CNC machining constraints.

Ensured the design allowed for accurate fitting of all auxiliary parts without issues.

Produced 3D printed prototypes of the crankcase and cover to verify dimensional accuracy and fit.

Conducted rigorous testing to ensure the prototypes met all design specifications and performance requirements.

Made necessary adjustments to the CAD models based on prototype testing feedback.

Collaborated with CNC machining experts to produce a machined prototype from aluminium.

Focused on optimizing the design to reduce machining time and costs, ensuring the product was cost-effective for production.

Conducted final tests on the machined prototype to confirm all components fit accurately and the design was ready for production.

Outcome

The reverse-engineered CNC crankcase and cover for Piaggio/Gilera 2-stroke scooters were successfully designed, prototyped, and tested. The final product met all performance and manufacturing requirements and is now available for sale on the PM Tuning website.

Impact

Client Satisfaction: PM Tuning was extremely pleased with the design and the efficient process from concept to final product.

Market Readiness: The product is now part of PM Tuning’s high-end offerings, catering to racing enthusiasts and tuning seekers.

Enhanced Reputation: The successful completion of this project has further solidified PM Tuning’s reputation as a provider of top-quality performance parts for scooters.

This case study demonstrates the importance of precise reverse engineering, thoughtful design optimization, and rigorous prototyping in developing high-performance automotive components.