Engine Run - 1600+ RPM

Project Overview: Designing, manufacturing, and assembling a fully operational tabletop heat engine. Focusing on precision machining and applying manufacturing processes, ensuring part compatibility through rigorous adherence to engineering drawings and tolerances. In total we designed and machined over 15 parts.

• CAD Design and Modeling:

  • Developed detailed part and assembly-level CAD models using SolidWorks.

  • Ensured digital connectivity and associativity between components to facilitate accurate machining and seamless assembly.

• Precision Machining:

  • Machining critical components. Such as those in the pictures below (piston flange, mounting block, web, and piston).

  • Utilizing manual and CNC machinery such as lathes, milling machines, and bandsaws, achieving stringent tolerances and surface finishes.

• Part Specifications and Manufacturing:

  • Following detailed engineering drawings specifying dimensions, tolerances, materials, and finishing techniques.

  • Integrating off-the-shelf components from suppliers such as McMaster-Carr, ensuring compatibility and reliability.

• Assembly and Integration:

  • Assembling components with careful attention to alignment, clearance, and functionality, guided by motion studies and assembly videos.

  • Performing tolerance stack-up analyses to ensure assembly-level accuracy and operational integrity.

• Testing and Validation:

  • Conducting initial operation tests verifying mechanical performance and part compatibility.

  • Evaluating thermal impacts on non-metal materials, ensuring material suitability under operational temperatures.

Skills and Tools:

• Machinery and Tools: Lathe, End Mills with .gcode and .pt4 complex patterns

• CAD Software: SolidWorks (3D modeling, assemblies, engineering drawings)

• Techniques: Precision Machining, Geometric Dimensioning and Tolerancing (GD&T), Tolerance Stack-Ups, Metrology

• Materials: Aluminum, Brass, Stainless Steel, selective 3D printing