Contents

INTRODUCTION.....................................................................................1
SAFE USE OF WORKSHOP FACILITIES........................................2
THE MANUFACTURING OF THE DOLLY STERLING ENGINE
.......................................................................................................................2
THE USE OF THE CNC MACHINE AND OTHER TOOLS......4
ASSEMBLING THE WORK PIECE.................................................4
TESTING THE PRODUCT.................................................................5
EVALUATION.......................................................................................5
SUGGESTIONS FOR IMPROVEMENTS.......................................6
DESIGNING A FLAT BOTTLE OPENER.........................................6
Metal stamping....................................................................................7
Stages of manufacturing the bottle opener.............................7
CONCLUSION..........................................................................................7
REFERENCE.............................................................................................8

INTRODUCTION

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Manufacturing technology provides the tools that enable production of
all manufactured goods. It provides the productive tools that power a
growing, stable economy and a rising standard of living. It is simply the
transformation of raw materials into finish product. (Mebrahtu, H.,
2010)

The report focuses on the task to make a Dolly sterling engine including
the safety of making it and Designing a flat bottle opener.

The purpose of the task given to the student is to enable the individual
have a feel and a picture of what manufacturing is and what it is about. It
gives the student more knowledge on manufacturing, materials and
skills.

SAFE USE OF WORKSHOP FACILITIES

It is very vital to know the safety of using workshop facilities, involving

the manufacturing of a product. This is essential in order to avoid
potential hazards. An important factor that determines professionalism
in manufacturing is the ability to know the safety and to submit to the
regulations of safety depending on the company or department. The
safety procedures are made to minimise the risk of getting injured or
killed.

Complying with the health and safety legislation and university

departmental requirements, the academic staff in charge of this
manufacturing module was aware I was in the workshop to use the
equipment. Before using the workshop facility it was necessary to be
properly familiar with the operation of the equipment and the emergency
procedures. It was compulsory for me to use safety glasses, foot wear and
lab cloth. I did not run around in the laboratory, and in the case of
malfunction of the machine or equipment I consulted the lecturer. I did not
make an attempt to bring food or drink in the laboratory.

 It was very important for me to know the location of the

emergency equipment and how to use them.

 I never blocked the safety equipment or doors to keep clear from

any danger. I was able to familiarise myself with the emergency
procedures, facility alarms and building evacuation routes.

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  I was aware of the personal protective equipment and how to use
them.

 When I was feeling dizzy in the workshop I left the place in order
to avoid health risk.

 The time I was in the workshop I was calm and did not rush in
making any work piece.

 I avoided distraction when working and tried not to be a

distraction.

 Before using a work surface I made sure it was at a comfortable

height with plenty of room to set out the tools and work piece.

 I never smoked in the workshop.

 It was necessary to keep the floor area clear and wipe up all spilled
liquids immediately to prevent slipping hazards.

 I enjoyed using the manual drilling machine, but I was putting on

safety goggle to prevent waste materials moving randomly to get
into my eyes. When making a work piece using a machine, the
technician or coordinator in manufacturing is always present to
avoid any risk.

THE MANUFACTURING OF THE DOLLY STERLING ENGINE

The making of the sterling engine involves different work pieces and
different ways of making these work pieces. It will be complex going
into full details of how the sterling engine was manufactured but easier
to give a visible summary of how the product was made.

Basically before making the sterling engine, it was necessary to work in

groups in order to meet up with the given time in manufacturing the
sterling engine. Most work piece was made using the CNC machine. CNC
(computer numerically controlled) machines are programmed and
controlled by computer in order to provide little set up times and the
flexibility to perform wide range of associated task. CNC machine brings
accuracy, efficiency, productivity and safety over other forms of metal
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forming or working equipment. The table containing the work piece and
the materials are made using the CNC machines.

Work piece Material

Base Aluminium
Bush Brass
Central block displacer Aluminium
Coupling block Brass
Cylinder plates Aluminium
Displacer flywheel Cast iron
Displacer shaft Silver steel
Displacer cylinder flange Brass
Displacer shaft guide Brass
Displacer cylinder Steel pipe
Fly wheel shaft Silver steel
Heat sink Aluminium
Power piston Cast iron
Power cylinder Mild steel
Power fly wheel Cast iron

The remaining work pieces were made without the CNC machine mostly
by hand. I remember making the gudgen pin, piston pin and 3mm dowel
by cutting it with a saw depending on the dimension given. The bolt and
screws were provided, and the displacer con rod was made by hand
using certain tools. The next paragraph provides a clear detail of the
main work piece needed to make the sterling engine.

The workshop materials used to manufacture the Stirling include: base,

bush 2 off, Centre block, power con rod, gudgeon block, transfer plate,
displacer flywheel, power flywheel, flywheel shaft, heat sink, power
cylinder, power piston, displacer cylinder, end cap, M4 shoulder screws
crank pin 2 off, brass washers crank pin 4 off, roll pin piston pin, roll pin
gudgeon pin, M5 socket head screws, M6 cap head screws, and dowel.
Each work piece has its own manufacturing process.

Reviewing each work piece;

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Power cylinder: The power cylinder is open at both ends and machined
from solid.

Power piston: The power piston is machined from a suitable piece of

cast iron, the piston is finished smooth. A precision gas tight fit is
essential for the engine to run at a good speed which is friction free.

Power con rod: The power con rod is shaped from 3mm BMS flat bar,
shaped and then drilled at one end to take the gudgeon pin and the other
end the crankpin shoulder screw.

Displacer cylinder: The displacer cylinder is made from copper tube

with the hot end closed with a compression fitting and the cold end
soldered to the flange.

The displacer: The displacer is made from a machinable ceramic that

does not conduct heat from one end to the cold end.

Displacer rod: The displacer rod guide brush is machined and reduced
at one end and threaded M6, the brush is centre drilled, and reamed to
take the displacer rod. The drive mechanism contains central aluminium
alloy block, 8mm hole is drilled laterally.

Power flywheel: The power flywheel is machined from 50 mm diameter

mild steel, the inner flywheel is drilled and tapped M5 to take a grub
screw.

The displacer flywheel: The displacer flywheel is similar to the power

flywheel except the crank pin is 11mm off centre, giving a 22 stoke.

The heat sink: is turned from aluminium bar and should be a tight fit
unto the displacer cylinder.

THE USE OF THE CNC MACHINE AND OTHER TOOLS

The influence of the CNC machine in manufacturing the work pieces

contributes to saving the time spent to make it and involves less energy
usage. The dimensions needed to produce the work piece is marked
using the machine. When the work piece is placed in the machine the Z
axis is set to zero and the Y and X are also set, after configuring the CNC
machine, the machine operates according to the programme until it cuts
to the required size. The constant speed used for cutting the component
was 1500 rev/min. As the machine cuts to a particular size, the
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measurement was examined to be certain of the amount left to be
removed; this is done progressively until the exact size needed is
attained.

Additionally, other machines and tools were used for the finishing of the
work pieces. The tools were used for drilling, filing, files, smoothing,
threading, and some hand tools. Once the exact size of the work piece is
cut using the CNC machine, depending on what is needed holes were
bored using drilling machines. The edges in the holes after drilling were
removed using the files. Smoothing was done using sand papers.

ASSEMBLING THE WORK PIECE

After making each work piece it was necessary to assemble it to make

the Dolly sterling engine. It was easier to assemble the assigned product
compared to making each work piece. The two cylinders made were
placed parallel to each other and attached on the opposite sides of the
plate. One of the cylinder houses the displacer, whereas the other is the
power cylinder. The power piston con rod and the displacer rod run
parallel to central block consisting of a flywheel on the power side and
the other flywheel on the displacer part. The complete work piece were
finally joined together and fitted to the base. The expansion of gas,
increased pressure and compression are transmitted from the cylinder
to the other through a hidden connecting passage drilled through three
cylinder plate in such a way that the working air is well contained
between the two cylinders.

Sterling engine after assembling 1

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TESTING THE PRODUCT

After the assembling, it was necessary to test the engine, to know if it

works accurately. To test the sterling engine a lighter was used to apply
heat to the displacer cylinder. When the displacer cylinder is hot, the
displacer inside the displacer cylinder starts to move. The air inside the
cylinder is compressed, which makes the power piston to rotate.

EVALUATION

First, it puts a smile on my face to see the sterling engine work. The dolly
sterling engine is a model for beginners. The work pieces used are easily
seen and easy to assemble. The sterling engine does not only work well
but it is also attractive because of the design. It is a good product to start
with as a potential Mechanical engineer.

Group Thursday 1

SUGGESTIONS FOR IMPROVEMENTS

Basically the idea for improvements should be based on what is needed

from the sterling engine. I think the design should be changed to a better
one. The sterling engine should be designed in a way it can be used
electrically, mechanically or even the use of solar energy. I also think a
lighter can be attached to the base instead of holding it and using a gas
lighter it can be powered alcohol burner. The sterling engine will be
made up of brass and aluminium.

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DESIGNING A FLAT BOTTLE OPENER
There are different methods for manufacturing products. It is relevant to
know the kind of material needed for the product.

The idea is to make a flat bottle opener; a bottle opener is a device that
enables the removal of metal bottle caps from bottles. To make this idea a
reality it is necessary to consider the type of environment the product will
be exposed to. The product will be exposed to different kinds of liquids and
has to be strong, basically has to be environmentally friendly. Stainless
steel is the material I have decided to use for my bottle opener because of
the following reasons;

1. it is less expensive(cheap)
2. it is resistant to rust or corrosion
3. It is good for hygiene. Cleaning stainless steel is very easy. Wiping the
surface down with liquid soap and water is usually all that is
required.
4. The ease of fabrication. It can be easily machined and shaped to what
we need.
5. Aesthetic appearance. It is attractive; considering not just making a
bottle opener but a key holder.
6. It has light weight. Light weight but strong enough for its purpose.

After choosing the material, the next thing to do is to choose the type of
manufacturing process for the product.

When thinking about the manufacturing process three things came into
my head;

 Metal laser cutting

 Water jet
 Progressive stamping

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 The three manufacturing process can do the job well; but one
process has to used. Reviewing the investment and average
operating cost;

 C02 laser - $300,000 with a 20kw pump and a 6.5’ x 4’ table

 Water jet cutting- $300,000 +
 Metal stamping- $50,000 to $300,000

Looking at the operation cost progressive stamping is definitely the

manufacturing process that is going to be used.

Metal stamping is a manufacturing process in which sheets of metal are

fed in a high tonnage press between stamping dies to cut and form metal,
producing completed or semi completed parts.

All stamping machines incorporate a form or die to give the stamped metal
the desired shape. The required shape will be attached to the stamp
machine.

I think progressive stamping is the best option for the mass production of
the bottle opener; many high production of stamping manufacturers are
capable of 30 to 80 stamping stokes per minute. Stamping manufacturing
processes include the following specific manufacturing processes or
techniques:

 Fine blanking
 Deep drawing
 Multi slide stamping
 Four slide stamping
 Wire forming
 Progressive stamping

Fine blanking is a unique form of blanking which not only produces

finished edges on a cut part but also works to close tolerance,

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 attaining a superb consistency over high volumes of production. Fine
blanking I performed in a die. (Suchy. I., 1998)

Stages of manufacturing the bottle opener.

1. The first part is to know what you want to manufacture. The
size and shape.
2. The second part is basically choosing the material suitable for
the bottle opener.
3. The third is to determine the manufacturing process.
4. Packaging for the distribution of the bottle opener.

CONCLUSION
The manufacturing module supported the students to have a clear view of
what manufacturing is not only theoretically but also practically. The
manufacturing of the dolly engine gives the student a little experience on
how to use manufacturing tools. After the manufacturing of the sterling
engine it gave the students a visible picture of what manufacturing is, but it
is be excellent if the students are given more time to understand the
machines and how to use them.

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REFERENCE

Engineers edge, 2000-2011. Metal stamping manufacture review.

Engineer’s edge, [online] available at
http://www.engineersedge.com/manufacturing/metal_stamping.htm
[accessed 20 march 2011]

Hood-Daniel, P. and Kelly, J.F, 2009. Build your own CNC machine [e-book].
New York: Paul Manning. Available through
http://books.google.co.uk/books?
id=wRNQ16R2bD0C&printsec=frontcover&dq=cnc+machine&hl=en&ei=N
2ixTeKCJMTrsgb3-
7TgDA&sa=X&oi=book_result&ct=result&resnum=2&ved=0CEkQ6AEwAQ
#v=onepage&q&f=false [accessed 10 April 2011]

Mebrahtu, H., 2010. Introduction to manufacturing process and part

programming. (Handout) Chelmsford: Anglia Ruskin university, faculty
building

Suchy, I., 1998.Handbook of die design. McGraw-Hill Professional

Swift, K.G and booker, J.D., 2003.Process selection from design to

manufacture (second edition). Oxford: Elsevier Ltd.

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