TECHNICAL REPORT STEAM ENGINE

FOR

MANUFACTURING PROCESSES LAB ETME/SVEN 2117 DEPARTMENT of ENGINEERING TECHNOLOGY UNIVERSITY of ARKANSAS/LITTLE ROCK From

August 8, 2012

INTRODUCTION
The objective of this experiment is to manufacture a steam engine model, emphasizing on the various manufacturing processes, materials and tools used during the process. The steam engine was a great invention that in one way heralded the industrial revolution. A steam engine is a eat engine that produces work, and the input is superheated steam. A steam engine is an external combustion, because unlike gasoline engine, the combustion takes place outside the cylinder of the steam engine. The main challenge in producing the steam engine was making the cylinder inner bore with close tolerances. Various people are credited for developments in the steam engine like Thomas Newcomen and James Watt, but manufacturing the steam engine commercially was an issue. John Wilkinson is credited for building the first boring machine that could be used to obtain accurately bored cylinders for steam engine. This machine was then used to bore the cylinders for the first commercial steam engine. We can hence understand the importance of development in manufacturing technology for production of new age machines and products.

PROCEDURE
The manufacturing processes used for producing the various components of the steam engine have been outlined.

Piston
1. Rough cutting rough cutting was first carried out to chunks of extra material quickly. The band sawing machine was used for this process and the tool was a saw blade @50 RPM. 2. Measurement the piston as measured using a height gauge 3. Side cutting sides were cut using a lathe machine 4. Edge finder done using milling machine @ 1115 RPM 5. Side milling side milling was carried out using a milling machine by engaging the end milling tool @ 1750 RPM

Shaft
1. Rough cutting rough cutting was carried out using the band sawing machine @ 50 RPM. 2. Measurement measurement was done using a height gauges and required dimensions were appropriately marked. 3. Edge finder done using a milling machine @ 1115 RPM. 4. Side milling side milling was done using a milling machine with the end milling tool @ 1750 RPM.

Upright
1. Rough cutting - rough cutting was carried out using the band sawing machine @ 200 RPM. 2. De-burring deburring was done to remove unwanted material using belt sanding machine. 3. Measurement measurement was carried out using a height gauge and necessary markings for further machining was carried out.

4. Centre drilling milling machine using the centre drill tool @ 1115 RPM 5. Side milling carried out using milling machine engaging the end milling tool @1750 RPM 6. Side milling carried out again using milling machine engaging the end milling tool @1750 RPM 7. Side milling carried out again using milling machine engaging the end milling tool @2750 RPM 8. Side milling carried out again using milling machine engaging the end milling tool @2750 RPM 9. Centre drilling - milling machine using the centre drill tool @ 1115 RPM 10. Side milling - carried out again using milling machine engaging the end milling tool @1750 RPM

Cylinder
1. Rough cutting - rough cutting was carried out using the band sawing machine @ 200 RPM. 2. Side milling carried out using milling machine engaging the end milling tool @2720 RPM 3. Edge finder done using a milling machine @ 1115 RPM. 4. Corner drill done using the milling machine with corner drilling tool @ 1115 RPM 5. Drilling done on the milling machine using the 1/8 drill bit @ 1115 RPM 6. Centre drilling milling machine using the centre drill tool @ 1115 RPM 7. Drilling done on the milling machine using the 12 drill bit @ 1115 RPM 8. Centre drilling milling machine using the centre drill tool @ 1115 RPM 9. Drilling done on the milling machine using the 13/64 drill bit @ 660 RPM 10. Reaming reaming operation was done on the milling machine @325 RPM 11. Tap tapping was done on the tapping machine using the 10.32 tool. 12. Edge finder done using a milling machine @ 1116 RPM

Base
1. Rough cutting - rough cutting was carried out using the band sawing machine @ 200 RPM. 2. De-burring deburring was done to remove unwanted material using belt sanding machine. 3. Side milling carried out using milling machine engaging the end milling tool @2750 RPM 4. Side milling carried out again using milling machine engaging the end milling tool @2750 RPM 5. Centre bore drill carried out on the milling machine using the #8(.194) drill @ 1750 RPM. 6. Centre bore drill carried out once again on the milling machine using the #8(.194) drill @ 1750 RPM.

PRECAUTIONS There are certain general precautions that must be observed while operating with machine tools Protective glasses must be worn while job is engaged, else flying chips might enter the eye. All the clamping devices must be tight and all the spanners must be removed before rotating the spindle of the lathe machine or milling machine. Do not touch components just after machining as the components generally get heated up after cutting operations. Clothes should be full and should not be loose; shoes must be worn at all times. Machine guards must be engaged before switching on the machine Long hair, tie, hanging mobile phones must be tightened up Never leave a machine unattended CONCLUSION The steam engine parts were hence manufactured. The parts were assembled to complete the steam engine model. The finishing of the components is an issue that must be taken care of. The parts we manufactured lack good surface finish and the irregularities are visible by naked eye. It is however a matter of experience and working more with these machines should give us more practice. From my experience, I learned that the speed and feed rates have great effect on the surface finish of the components.