Author Topic: Brayton Readymotor.  (Read 1629 times)

Offline Alyn Foundry

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Re: Brayton Readymotor.
« Reply #15 on: July 19, 2020, 04:16:14 PM »
Another foray into the dim recesses of my workshop to find....

Jo should be suitably impressed by the " special coating " on this casting, done over 16 years ago.

Offline Jasonb

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Re: Brayton Readymotor.
« Reply #16 on: July 24, 2020, 07:27:55 PM »
Well with little response to Grahams enquiry about 3D printing for pattern making it was back to wood but with a modern twist, now what's next ;)


Offline Alyn Foundry

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Re: Brayton Readymotor.
« Reply #17 on: July 24, 2020, 08:18:48 PM »
Oh my goodness Jason....

That was mesmerising, I kept wanting to blow the shavings away !!   :)

What's next?   The Yoke, the yoke, the yoke....

Cheers Graham.

Offline Jasonb

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Re: Brayton Readymotor.
« Reply #18 on: July 24, 2020, 08:22:22 PM »
Or the spoke, the spoke + ten others :LittleDevil:

Offline Jasonb

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Re: Brayton Readymotor.
« Reply #19 on: July 24, 2020, 08:31:25 PM »
A little teaser for you, if the previous one was mesmerising this will make you cross eyed :o


My flywheel turned up quite nicely with no hard spots or voids and looks quite good with a lick of paint ;)

Offline Alyn Foundry

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Re: Brayton Readymotor.
« Reply #20 on: July 25, 2020, 12:01:12 PM »
Thanks Jason.

Let's put the flywheel on the back burner " for now but the finished picture looks stunning. I'm thinking you've set the tone for the colour though, that glossy Black really " pops "

I'm getting on nicely with the main base pattern just one more set of core prints to go and some Patternmaker's dowels to fit and its done.

Typically " factory fortnight " has started in the Midlands but I've been given a number to call next Tuesday so I can find out if they do " lost foam " work.

I watched the video, don't forget the core prints lol.... ;)

Cheers Graham.

Offline Jasonb

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Re: Brayton Readymotor.
« Reply #21 on: July 25, 2020, 01:01:42 PM »
Not forgotten, I thought it would be easier to do a "T" shaped piece for the print and bottom of the "U" shape and add the bit in the simulation to that otherwise its a lot of sawdust and a lot of slender tool sticking out of the collet.


Offline Alyn Foundry

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Re: Brayton Readymotor.
« Reply #22 on: July 25, 2020, 01:20:38 PM »
That looks beautiful Jason.

You've chosen some nice wood to work with, really tight grained, what is it made from? I particularly liked to use seasond Ash, Beech or the old favourite Pitch Pine.

I have to say that the pattern would have taken me several hours to make you can see the virtues of CNC!!

Cheers Graham.

Offline Jasonb

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Re: Brayton Readymotor.
« Reply #23 on: July 25, 2020, 08:14:49 PM »
There's no pallet wood in my workshop :ShakeHead: caps were beech and the yoke is maple. Now if i'd have had a couple of lumps of cast iron I could have cut out the middle man and made them straight off in iron which may even have been quicker as having to cut the draft angle in small increments takes quite a while

Enjoy


Just need gluing together and the internal corner where pattern meets print squaring off. What size holes do your dowels need as I can add them.
« Last Edit: July 25, 2020, 08:17:54 PM by Jasonb »

Offline Alyn Foundry

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Re: Brayton Readymotor.
« Reply #24 on: July 25, 2020, 08:39:27 PM »
Lovely, that deserves a big.... :ThumbsUp:

So you've glued one face to the " core print " leaving the other face for location dowels? nice idea. A simple rectangle of wood or metal will create the corebox to finish.

You've made patternmaking look easy....

Cheers Graham.

Offline Jasonb

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Re: Brayton Readymotor.
« Reply #25 on: July 25, 2020, 08:43:32 PM »
Not glued yet, I was going to clamp the two prints together and drill right through for the dowel holes before gluing which will save filling the outside of the holes if you let me know diameter.

Offline Alyn Foundry

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Re: Brayton Readymotor.
« Reply #26 on: July 26, 2020, 11:10:24 AM »
Good morning Jason.

A couple of short polished Brass pins at 6mm diameter will be more than adequate Jason.

For more repetitive work  " cabinet makers dowels " were used, the pins were Steel, bullet pointed and fitted into a Brass socket. It enabled the two parts to disconnect readily.

Cheers Graham.

Offline Jasonb

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Re: Brayton Readymotor.
« Reply #27 on: July 26, 2020, 01:36:37 PM »
You will have to make do with 1/4" as I've drilled them now and the glue is drying. I thought your old pins are likely to be imperial.

I have used the pin and sockets on other patterns I have done for myself in the past but don't have many left if any.

Offline Jasonb

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Re: Brayton Readymotor.
« Reply #28 on: August 01, 2020, 10:20:18 AM »
Well with the flywheel design dcided upon Mr C has not had much luck finding reasonably priced 3D printing options or finding someone with a CNC router to machine a one use pattern so I had mentioned the possibility of me CNC cutting a pattern. Playing about with my available X & Y movement would have meant doing everything within the inside of the rim in three setups but the other option was to make separate spoke halves and build them into a rim.

So first step was to cut away everything but one spoke which was easy enough in Alibre, I left a segment of hub and the fillet where the spoke joins the rim so it can be cope cut to fit a shallow V in the rim.



It was then just a case of doing the CAM and pressing Go to end up with this which I'm very happy with straight off the machine.



 I glued the blank to a block of MDF with a sheet of paper between the surfaces which is easily parted with a sharp tap to a chisel and then a quick rub on abrasive to remove the remaining paper, actual machined surface needed hardly any sanding and most of that was just to remove a few whisps on the edges.



Video of the process, starting with the roughing out cuts with a 10mm 2-flute aluminium specific cutter followed by a long shank 6mm 4-flute ball ended cutter both at 5000rpm and feeds of 400 and 500mm/min respectively. It's a lot quieter than the video suggests as somewhere in teh editing/uploading I get some high frequency noise.



Offline simplyloco

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Re: Brayton Readymotor.
« Reply #29 on: August 01, 2020, 10:22:25 AM »
Very nice Jason, but I have to say on seeing it my first thought was of a beautiful mermaid! :NotWorthy:
John