Software Helps Race-Team Mechanics Become CNC Programmer-Machinists
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Reprinted From: Modern Machine Shop Magazine Shops Using Technology BETTER PRODUCTION Software Helps Race-Team Mechanics Become CNC Programmer-Machinists R acecar drivers are programmed for speed. So, it shouldn’t be any wonder that driver Conrad “Connie” Kalitta would push for his company, Kalitta Motorsports of Ypsilanti, Michigan, to begin making some of its own racing components instead of waiting the lengthy lead times often associated with outsourcing. By selecting GibbsCAM software from Gibbs and Associates (Moorpark, California), the company was able to better control both time and cost for making racing components. Although Kalitta Motorsports was founded in 1959, it wasn’t until about eight years ago that it seriously began to consider making some of its own components in-house. It already had a Bridgeport and a manual lathe for making simpler components, but it purchased most of its wear parts. Mr. Kalitta’s goal for making components in-house was to reduce component costs, gain control over quality and eliminate lengthy lead times. Ideally, the company would also gain the flexibility to make custom components without the expense of outsourcing prototypes and modifications. If successful, it would start making components for other teams as well. At that time, Kalitta Motorsports didn’t have a CNC machinist, CNC programming software or a CNC programmer, so its two machines were primarily used by Scott Finnis, a cylinder head mechanic who traveled with Doug Kalitta’s racing team from 1993 to 2006. Mr. Finnis learned to use the machines off-season, without any training. In 2006, the company acquired a three-axis Fadal 6030 CNC for Mr. Finnis to program and operate, even though he had never used a computer or CNC. In preparation, he purchased a PC to learn computer basics at home. Because Mr. Finnis lacked CNC experience, the shop needed CNC programming software that would be easy to learn and use, but would allow easy migration into higher levels of CNC machining that the shop might require later. Kalitta selected the basic GibbsCAM package, which enables creating wireframe geometry. Mr. Finnis describes the learning experience as very straightforward. “It was really easy and everything just made sense,” he KALITTA MOTORSPORTS PROBLEM Outsourcing manufacture of component increased cost and time SOLUTION GibbsCAM software from Gibbs and Associates RESULTS Reduced component costs, increased quality control and flexibility for customization This magnesium fuel-distribution block, finished with an anti-corrosive coating, was cylinder head mechanic Scott Finnis’s first 3D machining project. He modeled the part with GibbsCAM and used the software to program the toolpath by machining both directly on the model and using extracted geometry for hole features. says. “After a two-day training session with the GibbsCAM Reseller, I started learning the CNC. Until then I had never used a CNC, so I broke a few tools, but I got up to speed quickly.” Mr. Finnis began using GibbsCAM to design and program parts and tooling. He quit traveling from race to race so that he could focus on CNC programming and machining. That same year, another mechanic, Dave Griffiths, also stopped traveling with the crew to do manual machining work in the shop while he continued porting cylinder heads. In 2008, Kalitta acquired a Haas SL-20 lathe followed by a Haas VF-4. By 2012, Kalitta Motorsports had grown to two Top Fuel dragster and two Funny Car racing teams in addition to its stable of National Hot Rod Association (NHRA) cars. The 10,000-hp engines of the dragsters and funny cars often exceed 320 mph in the 1,000-foot run and can go through an unpredictable quantity of parts in a weekend during the possible eight rounds of racing. Among various potentia

BETTER PRODUCTION Shops Using Technology Shops Using Technology Before using GibbsCAM Solids Machining, Mr. Finnis used wireframe modeling to design and machine parts. SolidWorks and GibbsCAM Solids Machining enabled the shop to redesign parts with flowing curves, rounded edges and thinner walls to reduce bulk and improve aesthetics. Here is a finished fuel distribution Y block and its new version, partially completed. fuel nozzle, a failing valve or an electrical problem can ruin a weekend with burned pistons and broken rods. To be prepared and allow for excessive damage at each race, each...

BETTER PRODUCTION Shops Using Technology Shops Using Technology Before using GibbsCAM Solids Machining, Mr. Finnis used wireframe modeling to design and machine parts. SolidWorks and GibbsCAM Solids Machining enabled the shop to redesign parts with flowing curves, rounded edges and thinner walls to reduce bulk and improve aesthetics. Here is a finished fuel distribution Y block and its new version, partially completed. fuel nozzle, a failing valve or an electrical problem can ruin a weekend with burned pistons and broken rods. To be prepared and allow for excessive damage at each race, each...