Deepak Test - Excel

Tools

Lathe

Types of Engines

  • Fig. 1-1 Engine Types
    • Small Engine and Equipment Maintenance by Donald R. Koloski and R. Bruce Radcliff, p. 179

CSI.edu Steam Engine Project

Reliable Steam Engines

Reliable Single Cylinder 405 Parts List

No Part Name Casting Number Material Quantity Status
01 Bedplate RSC 405 (1) ? 1 Work in progress (WIP)
02 Crankshaft RSC 405 (2) ? 1 WIP
03 Flywheel Casting #145 ? 1 Done
04 1“ Bearing Cap Casting #102 ? 1 Done
05 2.25” Bearing Cap Casting# 103 ? 1 Done
06 1“ L X 1.25” ID Shaft bearing OD 1.5“ Bronze 1 ?
07 2.75” L X 1.25“ ID Shaft bearing OD 1.5” Bronze 1 ?
08 1.25“ Thrust bearing bearing supply house ? 2 ?
09 Thrust bearing retainers bearing supply house ? 2 ?
10 Connecting rod Casting #109 ? 1 Done
11 Connecting rod 1-1/8” ID bearing CPD #110 Boston Brg Bronze 1 Done
12 Connecting rod 3/8“ ID bushing CPD #111 Boston Brg Bronze 1 Done
13 Crosshead Casting #113 ? 1 Done
14 Piston rod 7/16 Drill rod ? 1 Done
15 Piston Casting #119 ? 1 Done
16 Piston rings Automotive type ? 2 Done
17 Frame Casting #122 ? 1 Done
18 Cylinder Casting #126 ? 1 Done
19 Cylinder Cover Casting #128 ? 1 Done
20 Steam Chest Casting #131 ? 1 Done
21 Valve Casting #134 ? 1 Done
22 Valve Cover Casting #132 ? 1 Done
23 Valve rod 5/16 Drill rod ? 1 Done
24 Valve Knuckle / Rod End Casting #139 ? 1 Done
25 Eccentric Strap Casting #140 ? 1 Done
26 Eccentric Casting #141 ? 1 Done
27 Eccentric Driver Casting #142 ? 1 Done
28 Valve Stem Gland Casting #136 ? 1 Done
29 Piston Valve Gland Casting #124 ? 1 Done
30 Pipe Connector Casting #152 ? 2 Done
31 Valve Nut Threaded CPD #135 ? 1 Done

Part01 - Bedplate

  • Crank is hitting wall so change hole width from 5” to 6“

Part02 - RSC 405 Crankshaft

  • Grease Fitting
  • Step 1 - make crank web with holes for shafts, use remmer at slow speed
  • Step 2 -
  • Step 2 - insert shafts with loctite 603 and a pin to hold, could also press fit it
  • Questions
    • Chamfer size not give, assumed 1/16”
    • Fillet only shown at one location, assumed to be at 4 locations on crank
    • Where do the Bronze Bearings go?
    • What material is the crank? Assume plain carbon steel
    • Grease Fitting - Zerk (think same as Standard)
      • [Q] How do I find the Zerk fitting in the SolidWorks Design Library?
      • [Q] How do I make a part transparent?
      • [Q] How do I show cosmetic threads?
        • Tools → Options → Document Properties tab → Detailing → Shaded cosmetic threads (check on) - seems like it does NOT work
        • Step 1 - Hole Wizard
        • Step 2 - Thread (under Hole Wizard) used to cut threads
        • Step 3 - download Zerk fitting
        • Step 4 - Assembly
      • [Q] How do I create SAE threads (Zerk fitting is 1/4“-28 SAE-LT)?
      • 1/4”-28 has overall length of 35/64“, fitting thread type SAE-LT
      • What about using a button head to provide a smooth working surface, cost is $0.67 for 3/8” each at grainger.com
  • Fig. 1-1 Part 07 - RSC 405 Crank

Crankshafts

Keyway

  • End mill in milling machine
  • Key stock at Grainger
  • vblocks held in vice with parallels, hold work piece against base not movable part

Part03 - Flywheel

Jensen Part06 and Part07 - Flange Sleeve Bearing

Part06 and Part07 - Bronze Bearing

  • Part06 - length 1.00”, Inner Diameter (ID) 1.25“
  • Part07 - length 2.75”, Inner Diameter (ID) 1.25“
  • Sintering furnaces for bronze, iron and stainless steel applications. Does this make the material porous to oil? Symmco Inc
  • Fig. 1-1 Part 06 and 07 - bronze bearing

Manufactures

  • Boston Bearing
    • Cast Bronze Sleeve Bearing sold at applied.com
  • Bunting
    • sold at applied.com
  • National Bronze Mft Company
    • Eric Wiesemann (ericw@nationalbronze.com) - do NOT sell split connecting rod bearings
  • GGB Bearing Technology
    • sold at applied.com

Part08 - Thrust Bearings

  • 1.25” Thrust Bearings from a bearing supply house
  • It seems I need a collar on the crankshaft to transfer axial thrust into the thrust bearing

Part09 - Thrust Waster

  • Symmco 1.25“ ID and 2” OD (Mfg No. ST-4064-4) cost \$2.71 from applied.com

Part10 - Connecting Rod (conrod)

  • Chevy 350
    • Speedmaster Part# 746-PCE274.1003 Connecting Rods Small Block Chevy 350
      • cost \$187.50 from jegs.com, use full floating pins so no bearing/bushing needed on the pin end bore
    • Federal Mogul Part# R18AJ
    • Mahle Clevite Part# CR-1009
    • Enginetech Part# ECR301
  • Off-the-shelf mass produced connecting rods
  • Engine Tech used by Qualified Automotive - can search parts
  • Crankpin Bearing
  • Demotor Performance \$129 for 8 Connecting Rods for Chevy SBC 350 - issue 1) uses 12-point head style instead of hex bolt, 2) need to buy split bearings
  • Eagle Speciality Products eaglerod.com - SIR5700BPLW connecting rod
    • jegs.com - cost \$240 for 8 rods
    • jegs.com - cost \$252 for 8 rods, bushed piston pin Eagle Part# SIR5700BBLW
    • jegs.com = cost \$33 for 1 rod, Eagle Part# SIR5700BP1
  • Fowler Engines Connecting Rods
    • Cost \$410 for 8 - Part# 12495071 - Connecting Rod Kit
    • Part# 10108688 - connecting rods
    • Part# 17800761 - connecting rod bearing kit for 350 and 383 engine
  • Connecting rod dimensions see Technical Graphics Communication, 4th by Bertoline p. 1051)

Jensen Connecting Rod

Part11 - Connecting Rod Bearing

Part 12 - Connecting Rod Bushing

Part15 - Piston

Part17 - Frame

  • Crank is hitting bottom of the frame, change radius from 2.5“ to 3”
  • Need to remove arc at bottom

Schedule of Operation

  • Need to cast part then machine

Part 31 - Valve Nut

Materials and Supplies

Graphite String

  • Packing yarn adding graphite
  • Keith i make my graphite packing from a soft cotton string and shave graphite from a soft pencil and work it into the string this works very good for me and it is better then what i can buy.
  • Blackgates Engineering

Grease Fittings

Steam Cylinder Oil

  • Valvata
  • Superheater steam oil from Blackgates Engineering, see comment on Part 18 - Large Horizontal Steam Engine Rebuild by Keith Appleton
    • Steam Oil - 90w Steam Cylinder oil 1 litre 10.25 UK
  • Lynch Oil, Scott Martens, scott.m@lynchoilinc.com, 208-431-2041, in Jerome ID
    • Mobil 600W Super Cylinder Oil, 5 gallon pail, is a high performance high viscosity oil designed for use in enclosed worm gears operating at moderate to high speeds and temperatures, and where heavy loads, slow speeds or high temperatures demand high viscosity oils. It is also intended for use in steam engine cylinder applications.
    • This product is formulated from high quality base stocks that are resistant to oxidation and thermal degradation, and the build-up of harmful deposits caused by the high operating temperatures of steam cylinders. It protects against rust and corrosion and provide good film strength and excellent lubricity and resistance to water washout.
  • PGO-FGL-460 Synthetic H-1/Food Grade Work Gear Lubricant (Mfr. No. L0813-057) used for worm gears, cost \$84.77 gal from applied.com
  • Lubriplate Gear Oil - Series SPO-222, AGMA No. 2 for high sliding action in worm gears, cost \$56.79 gal

Silcone O Rings

Painting

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