Mechanical production of stirling Engine

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I. Introduction
1. Turning Machine
1.1 Installation of Cutting tool
-Cutting tool: For installing the
cutting tool of turning machine, first
we should choose the cutting tool
which has a good cutting edge and fit
to the work. Then we install the
cutting tool in to the Tool post.
-Tool post: Take the cutting tool to
touch the dead center of tailstock
quill for reference. Make sure that the cutting edge is at the center of the
dead center. Then tight the cutting post and make sure that the cutting tool
is fixe. Put the tool post between 300-450 angle (with axe X) to avoid
crashing with the spindle chuck. Next tight up all the screws to make sure
that they are all tight.
1.2 Installation of Working part
-Work part: For install the work part, first we cut the work part which
depends on our requirement.
-Spindle Chuck: Setup work part in the
chuck in length 10mm-15mm in the right
position and tight up. Check the work part
by use the cutting tool as reference for
makes sure that the work part is in the
center of spindle.
1.3 Operation of Turning machine
After install the cutting tool and the work part, first we choose the
velocity of spindle by spindle speed which is confirm to the metal of
work part. Turn on the machine for give the real speed to the work
part. Next we give the speed to feed rate that response to the material
of the work part and also the cutting tool. The various angles, shapes,
and sizes of a single-point cutting tool have direct relation to the
resulting surface of a work piece in machining operation. Different
types of angle such as rake angle, side rake angle, cutting-edge angle,

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relief angle, nose radius exist
and may be different with
respect to the work piece. Also,
there are many shapes of single-
point cutting tool, such as –
shaped and square. Usually, a
special tool holder is used to
hold the cutting tool firmly
during operation.
 The relative forces in a turning operation are important in the design
of machine tools. The machine tool and its component must be able
to withstand these forces without causing significant deflection,
vibration, or chatter during the operation. There are three principal
forces during a turning process.
 The cutting or tangential force acts downward on the tool tip
allowing deflection of the work piece upward. It supplies the energy
required for the cutting operation. The specific cutting force required
to cut the material is called specific cutting force. Cutting force is
depends on the material.
 The axial or feed force acts in the longitudinal direction. It is also
called the feed force because it is in the feed direction of the tool.
This force tends to push the tool away from the chuck.
 The radial or thrust force acts in the radial direction and tends to push
the tool away from the work part.
Speeds and feed for turning are chosen based on cutter material, Work
piece material, setup rigidity, machine tool rigidity and spindle power,
coolant choice, and other factors. The distance the tool advances into the
material in one revolution is called feed. It is specified as mm per
revolution (mm/rev).
2. Milling Machine
2.1 Installation of Cutting tool
 Firstly, turn off the machine before install the cutting tool.
 Then, screw the bolt on the top of machine and hold the head of
machine by a fabric or piece of cloth to avoid rotation of the knife.
 We use wrench to screw the bolt and if the bolt is too tight, we can
use aluminum hammer to hit the wrench for loosen the bolt easily.

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 Check the knife if it has metal pieces stick on
it or not. You have to clean it and apply the
lubricant every time you use it.
 Take out the old cutting tool and put your new
knife to the hole properly to avoid cutting your
hand or finger.
 Finally, we screw the bolt tightly.
2.2 Installation of Working part
 First of all, you need to have two steels
rectangular-shaped for deposit the work part.
 After put these two steels below the work part, you have to use axis
Y (move toward and backward) or the table cross hand wheel to
make the work part stable during work.
 Use steel perpendicular ruler to measure the work part and make sure
that it is perpendicular to the plan.
 Then, use axis X (move to the left and to the right) or table feed hand
wheel and axis Z (move up and down) or knee elevating handle to
adjust the work part close to the cutting tool.
2.3 Operation of Milling machine
 Check out the cutting tool and the work part again if they are
installed incorrectly. If not, it causes some problem such as the knife
breaks, the work part has been damaged…etc.
 Set the scale (mm) on the wheel of axis X,Y,Z for the size we want
to cut on the work part’s surface (0.1mm; 0.2mm;…).
 When you already adjusted the scale on axis X and Z, you have to
lock these two tables by the lock handle of each axis. This can
protect from sliding of table work.
 Adjust the speed of the knife and the speed of tables.

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 Check the water. If the machine runs out the water, put the water in
and press the green button.
 Turn on the water, set the faucet near the knife (not too close).
 In front of the machine, on the bottom part, there are two buttons
“Red Button” and “Blue Button”. When we start our operation, we
just press the blue button. And if the machine has problem or you
want to stop the process, we just press the red button.
 After pressed the blue button, rotate the wheel of axis X to push the
work part near the cutting tool.
 Moreover, just spin the table feed hand wheel slowly to move left
or right for cut the surface of work part.
 To protect yourself especially your eyes from the splash of hot
metal pieces during cutting, you should wear safety goggles.
 In the conclusion, when the work part is finished, we press the red
button.
3. Drilling Machine
3.2 Installation of Cutting tool
 First, we should choose the twist drill
which has a good drilling edge and fit
to the work (starting from small to
big). Then we install the twist drill
into the drill chuck.
 Then, take the twist drill tang to touch
the dead center of drill chuck slot for
reference. Make sure that the twist drill tang is at the center of the
dead center. Then tight the twist drill and make sure that the twist
drill is fixe. Next tight up all the screws to make sure that they are
all tight.
3.2 Installation of Working part
 First of all, you need to have two steels rectangular-shaped for
deposit the work part.
 After put these two steels below the work part, you have to use
axis Y (move toward and backward) or the table cross hand wheel
to make the work part stable during work.
 Use steel perpendicular ruler to measure the work part and make
sure that it is perpendicular to the plan.

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 Then, use axis X (move to the left and to the right) or table feed
hand wheel and axis Z (move up and down) or knee elevating
handle to adjust the work part close to the cutting tool.
 Use feed hand to handle for feed and during drilling hand it down
and up often to avoid the twist drill broken.
3.3 Operation of Drilling machine
 Check out the twist drill and the work part again if they are
installed incorrectly. If not, it causes some problem such as the
knife breaks, the work part has been damaged…etc.
 Adjust the speed of the knife
 Move the machine vice that is
equipped with jaws which
clamps the work piece to where
you want the drilling machine
do on your work steel. The vice
is bolted to the drilling table and
you can swivel through 360° on
a horizontal plane.
 Ensure for the cutting tools
running straight before starting
the operation and spin the hand
feed up and down to make the
twist drill in the spindle cut your steel.
 Avoid loose clothing and protect the eyes.

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II. Operation in Laboratory
1. Power Piston Cylinder
In this work part we have to use
cutting tool machine, turning machine,
drilling machine to process it.
 First, we cut metal for our
operation with length 40
mm with cutting tool
machine (include 15mm
for chuck)
 Second, we take our piece of metal to the chuck and start turning
machine to get the result with diameter Ø 29 mm.
 Third, we start turning process again with depth 11 mm and length
18 mm
 Fourth, Drilling process with diameter Ø 13 mm
Threading 4 through holds.

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2. Displacer Cylinder
In this work piece we have to use cutting tool machine, turning machine, drilling
machine to process it.
 First, we cut metal for our operation with length 49 mm with cutting
tool machine (include
15mm for chuck)
 Second, we take our
piece of metal to the
chuck and start turning
machine to get the result
with diameter Ø 29 mm.
 Third, we start turning process again with depth 13 mm and length
28 mm
 Fourth, Drilling process with diameter Ø 14 mm length 26 mm
 Threading 4 through holds.

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3. Displacer Piston
In this work part we need to process in cutting tool machine, turning machine,
drilling machine.
 First, we cut metal for our
operation with length 82 mm
with cutting tool machine
(include 15mm for chuck).
 Second, sawing
 Third, drilling process with
diameter M 3.
4. Power Piston

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In this work part we need to process in cutting tool machine, turning machine,
drilling machine.
 First, we cut metal for our operation with length 33 mm with cutting
tool machine (include 15mm for chuck).
 Second, sawing
 Third, drilling process with diameter M 3.
5. Flywheel
In this work part we need to process in cutting tool machine, turning machine,
drilling machine.

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 We need to take the cylinder
that has diameter D= 27 mm
and length L= 35 mm, we
need 4 cylinder.
 Practice: Turning (facing, cut
off, drilling) and Drilling (1
through hold).
6. UPPER BASE
 We need to take it that has length L= 74 mm, W= 34 mm, H= 12 mm
 Practice: Drilling (12 through holds, 1 blind hold) and Milling (facing)

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7. Body
 We need to take the body that has L= 124 mm, W= 34 mm, H= 12
mm, N= 2.
 Practice: Threading (4 blind holds, 1 through hold) and Milling.
8. Base

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 We need to take the base that has L= 100 mm, W= 69 mm, H= 12
mm, N= 2.
 Practice: Drilling (2 through holds) and Milling.
9. Power Piston Connection Rod and Displacer Connection Rod
 We need to take the rod that has L= 58 mm, W= 10 mm, H= 2 mm,
N= 4.
 Practice: Drilling (2 through holds) and Sawing.

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III. Conclusion
After finish the work, we should remove some tools such as cutting tool,
wrench, steel ruler, aluminum hammer and other tools in to the place origin
and clean up all the metal pieces and the water in the machine by using brush
and fabric. Clean the surface around the machine and lubricate some parts in
the machine to make it clean and available for the next use.