Methods
The die grinder is the stock in trade of the head porter and are used with a variety of carbide cutters, grinding wheels and abrasive cartridges. The complex and sensitive shapes required in porting necessitate a good degree of artistic skill with a hand tool.
Until recently, CNC machining was used only to provide the basic shape of the port but hand finishing was usually still required because some areas of the port were not accessible to a CNC tool. New developments in CNC machining now allow this process to be fully automated with the assistance of CAD/CAM software. 5-Axis CNC controls using specialized fixtures like tilting rotary tables allow the cutting tool full access to the entire port. The combination of CNC and CAM software give the porter full control over the port shape and surface finish.
Measurement of the interior of the ports is difficult but must be done accurately. Sheet metal templates are made up, taking the shape from an experimental port, for both cross-sectional and lengthwise shape. Inserted in the port these templates are then used as a guide for shaping the final port. Even a slight error might cause a loss in flow so measurement must be as accurate as possible. Confirmation of the final port shape and automated replication of the port is now done using digitizing. Digitizing is where a probe scans the entire shape of the port collecting data that can then be used by CNC machine tools and CAD/CAM software programs to model and cut the desired port shape. This replication process usually produces ports that flow within 1% of each other. This kind of accuracy, repeatability, time has never before been possible. What used to take 18hrs. or more now takes less than 3hrs.
Valves and valve seats are ground with special equipment designed for this purpose.
Read more about this topic: Cylinder Head Porting
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