Jan. 2018

Bluewater Bulletin

Bluewater Model Engineering Society Sarnia, Ontario

Vol. 33 No.3 December 2017 Editor John Lovegrove

Our next meeting will be on

January 8th, 2018 @ 7:30 pm

Northern Collegiate Room 128, Indian Road, Sarnia.

The December Meeting

Unfortunately, the meeting was rather poorly attended with only 8 of us present. It seemed to be a combination of iffy weather (snow) and several people suffering from colds etc. Our Treasurer was one of those absent so there was no report on our finances.

There was some discussion about obtaining small wrenches. Bruce Mannerow has some bolts on his howitzer chassis that are very difficult to reach. A few people talked about the ignition wrenches that used to be available from Sears. You are obviously out of luck with Sears Canada but checking their American website, they still offer these in both inch and metric sizes.

He has also been looking at measuring the large end of an internal taper. Getting an accurate measurement with digital callipers is really not feasible. However, if the hole is large enough and long enough to get the internal measurement part of the calipers inside, and you know the taper angle, it is then possible to take a measurement with the calipers (at the depth of the internal measuring part) and calculate the diameter at the outer end. (See the diagram later.) There was also some discussion about using an appropriately sized ball to carry out the measurement. The use of 2 balls was also talked about: Thinking about this; if appropriately sized balls are available, the approach can be used to measure the taper angle as well as the diameter at the end. (Again, more later.)

The geometry/trigonometry associated with the internal calliper technique is fairly simple but when one starts using balls for measurement it gets more complicated. Someone commented that it is possible to find all sorts of math related stuff on the web but that a lot of what comes up is erroneous.

The next item up for discussion was "Forged in Fire" as shown on the History Channel. Alan Olsen got involved in the discussion and there was general admiration for the techniques that were evolved in fairly early times to get the right combination of hardness at the cutting edge of a sword to hold that edge while maintaining sufficient ductility in the rest of

had ruined an earlier piece for another reason but pleased that I did not have a problem with the spindle drive because that would have been much more expensive to fix.

the blade so that it does not break during use. (I never cease to be amazed at the ingenuity and enormous effort that mankind has devoted to killing his fellow man.)

One other item Bruce came up with was the recent discovery of an underground factory created by Rover during WWII to enable them to escape destruction by the Luftwaffe. One asks how this could have remained secret for so long but a few years ago a lot of information started to become available about the Bletchley Park code breaking facility and one aspect which came to light was that people who worked there were sworn to secrecy on pain of very serious consequences. That secrecy was well respected and so it is not surprizing that many secret wartime activities have remained that way. (Just Google "Rover underground factory WWII" and all sorts of interesting stuff comes up.)

My Machining Problem

I talked about a problem I had with a milling cutter while machining the component described later in "Show and Tell." I have an ER type collet on my CNC mill and put a new end mill into this to start a machining operation. As it started into the cut the main spindle began speeding up and slowing down. My initial concern was that there was a problem with the motor or the controller so I paused the cut and checked the operation of the drive. It seemed to be OK so I re-started but the same thing happened, then, the drive stalled completely. When I looked again at what was happening, the depth of cut had increased as the cutter moved along so it was clearly "pulling" itself into the metal.

I discovered that what had happened was that the new cutter came with a film of preservative oil that I had not noticed when I took it out of its little box (I guess I just handled it by the flutes.) In spite of being tightened normally this film allowed the cutter to slip in the collet and dig itself into the workpiece. It also explains the drive speed hunting because of intermittent slipping in the rotational sense. When I cleaned off the lubricant and tried again, everything behaved normally but by this time I had ruined the workpiece. I was rather annoyed by this because I

to drill and tap the component to take a tube that will go to the bottom of the oil pan. (Sufficient metal has been left to do this.)

Show and Tell

Bruce has been working on the wheels for his howitzer. The rims are made of wood in 4 sections glued together then turned to the right size. He had a few problems getting things to work properly and had some rims disintegrate during the turning process. In all 6 starts were needed to get 2 successfully completed rims. He has

also completed the hub parts and has cast some of the spokes in thermoset resin. This is a picture of the "pipe boxes" (hub pieces) mounted on the axles:

This is one of the hub pieces with a couple of spokes:

Measuring Tapers

I have made a little more progress with my Sealion by completing the essential machining of the oil pan extender piece that makes it easier to connect with the inlet to the oil pump. This will also give me a reasonable oil capacity and will incorporate a screen to filter out debris.

It involved some fairly complex machining and I had the same success ratio as Bruce; needing 3 starts to get one item successfully completed. (One of the causes of failure was described above.) The first photograph shows the component on its own with the provision for a screen (yet to be made.)

The second shows the component temporarily attached to the underside of the engine block with the oil pump and connecting manifold in place. I still have

The following drawing illustrates what Bruce was talking about with calipers being used to measure a diameter D1, distance h from the top surface:

h1=l1 + d1 x (1 + sin(A))

2

The diameter at the outer end of the taper D can then be calculated using D1, h and the taper half angle A:

D=D1 + 2 x (H x tan(A))

The drawing below shows the situation where a ball of an appropriate size is used to get the measurement required. The diameter of the contact circle D1 can be calculated using the diameter of the ball d1 and the taper angle A:

D1=d1 x cos(A)

Given the depth of the top of the ball from the top surface; l1, the depth of the contact circle can also be calculated:

is basically a slip eccentric moved around by a helically splined system on the crankshaft and operated from the reversing lever. (I never did figure out exactly how it works but it will obviously not provide the variable cut-off that you can get with normal reversing gears.)

These values can then be used in the same formula as used for the calipers, to calculate D. The depth of the top of the ball inside the tapered hole would normally be measured using a depth micrometer. If the ball protrudes above the surface, a depth micrometer + blocks of known thickness (e.g. gauge blocks) would have to be used and the amount of the protrusion entered as a negative value for l1.

Earlier on I did mention the use of 2 balls to measure the taper angle. I did crank through the math involved and it turns out to be relatively complicated. I can go into it with anyone who is interested but it is probably not worth elaborating upon here.

A few more Pictures from my UK Vacation

Lake Coniston is in the English Lake District and is where Donald Campbell’s life came to a sad but rather spectacular end in 1967, attempting to break his own world speed record on water. (When we were there this time it was a rather damp, dismal day.)

This is a picture of the paddle steamer Kingswear Castle which appeared in the TV series "The Edwardian Farm." It sails on the River Dart and is based in Dartmouth.

This is the engine underneath the boiler.

(As I was saying, it is not easy to get good pictures of the machinery on boats.)

I did try to get some pictures of the boiler and engine but they did not turn out to be very worthwhile. Apparently, they were burning real Welsh steam coal which now seems to be available again.

Still on the marine theme; there is a rather nice Steam Gondola that runs on Lake Coniston. It has a locomotive type boiler with a 900 V twin engine underneath. They use compacted sawdust briquettes as fuel (something about carbon credits) and the engine has a rather interesting reversing gear which

Meetings for the rest of the Season

2018

January 8th

February 12th

March 19th (12th is March Break)

April 9th

May 14th

June 11th

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