Sterling Engine Fabrication
Precision manufacturing of critical power piston assembly components for a collaborative Sterling engine project, requiring air-tight tolerances and press-fit integration.
Overview
The Problem
Manufacturing critical engine components with extremely tight tolerances within limited machine shop access time, requiring air-tight seals and perfect press fits for proper engine function.
The Solution
Developed detailed process plans to maximize efficiency in the machine shop, implemented precise machining techniques, and executed iterative fitting procedures to achieve necessary tolerances.
Key Outcomes
- •Manufactured power piston assembly with verified
air-tight seal - •Achieved successful press fit between components
- •Completed all components within schedule constraints
My Role
Manufacturing Engineer
(2-person team)
Project Gallery
Full Sterling engine assembly running after successful integration
Power cylinder and base press fit together
Demonstration of the air-tight seal between piston and cylinder
Detailed process plan for manufacturing the power cylinder base
Design Challenges & Solutions
Time Constraints
With only a few hours of dedicated machine shop access each week and conflicting schedules between team members, we faced significant time pressure to complete complex machining operations with precision.
Strategic Process Planning
We created detailed process plans for each component that optimized machine time, planned tool changes, and anticipated potential challenges. This preparation allowed us to make the most of our limited shop time and avoid costly mistakes.
Air-Tight Tolerances
The power piston assembly required an air-tight seal between multiple components—any imperfection would prevent the engine from generating power efficiently or functioning at all.
Iterative Fit Refinement
Rather than aiming for perfect dimensions in a single machining pass, we strategically approached the piston fit with slightly oversized dimensions, followed by careful sanding and testing to achieve the perfect air-tight fit.
Press Fit Requirements
The cylinder and base needed to achieve a precise press fit, requiring exact dimensioning with minimal margin for error during the manufacturing process.
Press Fit Adaptation
When our initial press fit attempt wasn't perfect, we adapted by using the opposite end of the cylinder, demonstrating problem-solving skills and flexibility in manufacturing without requiring new materials or complete rework.
Impact & Results
Impact
Our precision-manufactured components contributed to a fully functional Sterling engine that successfully ran after final assembly and tuning. The project demonstrated both individual manufacturing skills and effective teamwork in integrating components from multiple student teams into a working mechanical system.
Manufacturing Precision
Achieved air-tight tolerances between piston and cylinder
Time Management
Completed all components on schedule despite limited shop access
System Integration
Successfully integrated with other teams' components for a working engine
Key Takeaways
- Practical experience with precision manufacturing techniques and tolerances
- Effective process planning methodology for complex machining operations
- Collaborative problem-solving approach to mechanical system troubleshooting
- Adaptability in manufacturing processes when facing unexpected challenges
Skills Developed
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