volume 4 number 12 winter ’00 the UltimateUltimate MercedesMercedes photo courtesy DC Sports nother year is behind us and the New Millennium lies before us . man, life can be such a blur. In this issue A of CNC Machining, things definitely get a little blurry, but bear with us, we always bring them back into focus. For our cover story we feature Ilmor Engineering. They supply the Mercedes-Benz engines that put the blur in CART and Formula One racing. We visit the new Ilmor Tech > volume 4 > number 12 > winter 2000 Center in Plymouth, Michigan, for a look at what it takes to build high-performance race engines. Then we move from the race track to the street for an > CONTENTS inside view at DC Sports, a company that has experienced a blur of rapid growth over the past few years. Brothers Darrell and Darrick Contreras (the DC in DC Sports) have FEATURES ridden the leading edge of the Sport Compact Car wave to DC Sports Exhausts the Possibilities 6 become one of the top manufacturers of performance parts for Hondas and Acuras in the world. We show how they Virtual Manufacturing? Get Sirius! 14 grew from producing five or ten exhaust headers a week to Ilmor Engineering Races into the New Millennium 18 pumping out more than 400, in addition to manufacturing a Grinding Out Precision at Mindrum 26 full line of suspension components, intake systems and other performance accessories. INDUSTRYNEWS In our story about Mindrum Precision, we look at how Editorial 2 this unique company has blurred the line between traditional CNC machines and precision grinders. You’ll see Five-Axis Bridge Mill Dedicated 3 how they use Haas VMCs and lathes to machine such exotic Trade Show Calendar 3 materials as glass, quartz and ceramic. PRODUCTUPDATE Then it’s on to college. We follow a group of women engineering students from California State University, New Haas Mini Mill on the Horizon 33 Northridge, as they “Shadow an Engineer” at Haas C-Axis Turning 33 Automation to see what engineering is like in the “Real VS-3 Hits Production 33 World.” We found their views quite interesting. High-Speed Machining: What to Expect 36 Also interesting is the blur of high-speed machining. It’s all the rage these days, but there’s still a lot of confusion RACINGREPORT about exactly what it is, when to use it and just how much Gordon off the Pace in 1999 4 benefit to expect. We’ve come up with the definitive answer: It just depends! To clarify the subject – bring it Sprague Takes NASCAR Truck Title 4 more into focus if you will – we perform a head-to-head Ilmor Logs F1 Driver’s Championship 5 comparison of standard machining versus high-speed machining under different cutting applications. EDUCATION But wait, there’s more! You’ll also find a piece on virtual Engineering Students Get Real 30 manufacturing, a look at the newest Haas products, the latest Race Report and more. THE MASTHEAD So, sit back, relax and enjoy! CNC Machining is published by Haas Automation, Inc., 2800 Sturgis Road, Oxnard, CA 93030 • 805-278-1800, Fax 805-988-6918. Postmaster: Return invalid addresses to Haas Automation, 2800 Sturgis Road, Oxnard, CA 93030-8933 postage guaranteed. CNC Machining is distributed free of charge by Haas Automation, Inc., and its authorized distributors. CNC Machining accepts no advertising or reimbursement for this magazine. All contents of CNC Machining are Copyright © photo courtesy DC Sports p 6.INSIDE: 2000 and may not be reproduced without written permission from Haas Automation, Inc. CNC Machining is distributed through a worldwide network of Haas Automation Distributors, and by DC Sports takes performance seriously. The company got its start making individual subscription request. Contact Haas Automation headquarters via mail or fax to be added exhaust systems for American Honda’s race team. Today, they bring race- to subscription list. Published quarterly. © Haas Automation, Inc. & CNC Machining Magazine proven performance to the street with products for Hondas and Acuras. names. Designed and Printed in the U.S.A. CPC # 1563572. www.HaasCNC.com 2000 > EDITORIAL by Denis Dupuis > INDUSTRY NEWS Five-Axis Capabilities Dedicated A Look into the New Millennium t is that time of the year again. Time excellent rewards, as well, in the form of We are blessed with so many to take stock of what we did last year higher reliability and reduced costs on things: good health, great friends, I and make our plans (budgets) for the the products that we manufacture. Our a good economy, the best quality new year. As I write this article, having goal of achieving ISO certification is on of life and some of the best and just attended the Haas dealer council target, and as we continue this program brightest people to work with every meeting, I am reminded of how tough into 2000 and beyond, everyone will day. What more could we ask for? 1999 must have been for you. Our benefit – our customers, our distributors I think I’ll upgrade that budget customers wanted lower prices, our and our whole company. for 2000. dealers wanted more margin and our employees wanted raises. It seems that we were squeezed from every direction. All-in-all it was a tough year for our industry, with the bottom line Haas Automation president Gene Haas recently visited suffering the most. While we were able Klune Industries, Inc., for the inauguration of the to remain profitable, it is difficult to be company’s newest additions to their stable of machine tools. positive when every time we turn Klune purchased a new Haas VB-1 five-axis bridge mill (the around the value of another “.com” second VB-1 off the production line) and a VR-11 five-axis rockets through the stratosphere, vertical machining center. Both machines seemingly with little effort. are hard at work helping Klune Ok, enough complaining, next capitalize on the growing advantages year can only get better… right? It’s of five-axis machining. Located in North planning time! As I try to peer into our Hollywood, CA, Klune Industries, Inc., future, I am persuaded that the new specializes in manufacturing and millennium will be better and brighter engineering for the for the machine tool industry, and aerospace, communications especially for Haas. I look at the new and related industries. products we have on the drawing board, and know that they will be great additions to our product line. More high quality products, made in the 2000 TradeShow Calendar USA, to help our customers solve their Show Name manufacturing problems – that’s & Location Dates Information something very positive to look HOUSTEX, APEX Jan. 25 – 27, 2000 Held at the George R. Brown Convention Center, this show attracts buyers from the forward to. Houston, TX oil, high-tech, aerospace & shipping industries. Haas products will be shown Last year’s launch of the Haas in booth #1101. Factory Outlet concept of distribution is moving along as scheduled. The SOUTH-TEC. APEX Feb. 29 – Mar. 2, 2000 This event attracts over 13,000 attendees to the largest Southeast machine tool programs these HFOs open up to our Charlotte, NC show. Haas Automation will be located in booth #2202A. customers – with their clear focus, WESTEC, APEX Mar. 20 – 23, 2000 North America’s largest annual metalworking and machine tool exposition with improved services and dedicated Los Angeles, CA 35,000 attendees and 725 exhibitors. Haas Automation is in booth #3229. employees – are positive affirmations EASTEC, APEX May 23 – 25, 2000 This is New England’s leading machine tool show that attracts more than 25,000 that the new millennium is starting W. Springfield, MA attendees. Haas Automation will be located in booth #2448. off well. The quality program that Haas IMTS Sept. 6 – 13, 2000 This is the largest biennial trade show in the Americas, attracting over 120,000 launched in 1999 has produced some Chicago, IL attendees and 1,400 exhibitors. Haas Automation will be in booth #8232. 2 CNC MACHINING WINTER 2000 3 > RACE REPORT RACE REPORT aas Automation’s involvement in the racing community is a beneficial Formula One However, late breaking news finds association that recognizes the close bond between precision driving On a brighter note, Ilmor the long-running Toyota sponsorship of earned another Driver’s AAR coming to an end, and powerplant Hand precision machining. Through technical partnerships and Championship with Mika choices up in the air for the 2000 CART sponsorship agreements, Haas provides race teams with the latest CNC Hakkinen driving the Ilmor- season. The AAR team is still dedicated powered Mercedes team car, to fielding at least one car, and rumor equipment. In return, Haas gains access to a network of cutting- leading the final race of the has it there may be a F– – – in the future edge racing facilities where prospective customers can see Formula One series (Osaka, for the American Eagles. Japan) from start to finish. Haas equipment making the parts that win races. For a detailed feature story on Precision Preparation Inc. Ilmor Engineering, turn to page 18. (PPI) Hendrick Motorsports Fontana, the final race of the season. With help All American Racers (AAR) CART Champ Cars Winston Cup Series from fellow Chevy Scott Pruett (#24) and 1998 PPG- CART Champ Cars Major changes took place with car driver/rival Ron Dayton Indy Lights champion Cristiano #24’s Rainbow Warrior team during the Hornaday, Sprague went AAR finished out the season with da Matta (#25) spent the year pushing last quarter of the ’99 NASCAR season. on to win the race by a two American-built Eagles running in Jeff Gordon finished out the year scant 0.266 seconds, capturing the CART series.