Team Effort
Eric Johansen is active in the Model Engineering community, and was approached by another active member looking to produce a replica of the Simplex engine. This member, Robert Washburn, along with Bob Paule, was working on creating scale mechanical drawings from a model built by an individual named Edgar L. Roy. Mr. Roy owned a full sized Simplex car from which he built the model but never produced working drawings for the engine. He loaned Mr. Washburn and Bob Paule, one of his models to disassemble and draw. Mr. Washburn asked Eric if he would be interested in producing a model of this engine as a prototype. In fact Eric was the machinist that this person was looking for. Over the years they have teamed up to produce a working model of the engine, including patterns and molds for the castings, and techniques for manufacturing. This has provided insight into the difficulties in producing a full sized version of this engine for production.
Manufacturing Techniques
This engine, like most, requires numerous techniques to produce each part (additional images). These operations need to be followed to restrictive tolerances so that all the parts will fit and operate together properly. For parts such as the crank case, timing cover, cylinders, manifolds, and connecting rods castings needed to be made using molds. After the castings were poured, machining, drilling, and tapping were required to allow the crank case to be able to seal properly together, and provide places for bolts to connect. Other parts such as the crankshaft or intake and exhaust valves are machined directly from bar stock utilizing a variety of techniques. For example initial roughing on the crankshaft was done using a horizontal bandsaw. The rough blank next went to the milling machine where the crank throws were roughed out and finally to the lathe where the journals were turned and polished. Most parts require a combination of machining techniques and more than one machine tool to produce a complete part. These techniques can provide valuable insight for students on how a piece of machinery is designed and built. This is useful in teaching classes on producing and manufacturing products in a machining plant.
Class Interactions
M.E.321 Industrial Processes labs meet weekly in the machine shop during the fall semester to engage in the production of Stirling Cycle engines. Along the way they are exposed to precision manufacturing techniques, mass production techniques, the operation and use of bandsaws, lathes, mills, and Computer Numerical Control (CNC) equipment, measuring instruments and their use, part inspection, and assembly techniques. Even though students use mass production techniques to achieve the necessary economy of scale each student gets to assemble and keep their own engine. The techniques learned and used are the same for both the Stirling engine and Simplex engine.
Sharing History
This model engine will be finished and demonstrated to the department, and then will be sent to the Miniature Engine Museum for display. This museums sole purpose is to display and preserve miniature engines and keep records of creators, design, and information about a larger engine that it may have been based on.
Community Development
Eric Johansen is an active member of the local antique engine club of fairbanks. This club meets weekly to discuss older engines and their maintenance.
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