Author Topic: MEM Corliss Attempt  (Read 15990 times)

Offline scc

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Re: MEM Corliss Attempt
« Reply #90 on: June 26, 2020, 12:18:47 PM »
 :popcorn: :popcorn: Thank you for the clear pics and explanations.......I'm following and learning.            Terry

Offline Larry

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Re: MEM Corliss Attempt
« Reply #91 on: July 30, 2020, 12:32:40 AM »
VALVE DISK - The Valve Disk is made from a piece of 1/8" (.125) scrap steel. It was machined to the outside rectangle dimension of .879" x 1.625". The hole pattern was laid out and consists of: (1) 1/8" (.125) hole; (4) .076" holes (#48 drill); and (1) 1/8" square hole. A .040" (#60 drill) hole was drilled in each corner of the 1/8" square hole ( 4 places). A 3mm end mill was used to plunge the center of this square hole. The 1/8" square hole was completed with pattern files. The 1/8" (.125) hole was drilled and reamed to .126". The four corner holes in tabs were drilled .076" (#48 drill). The end radii were cut out using a 1/4" 4FL end mill. The sides were cut out using a 1/4" 4FL end mill. The large 3/16" radius end tab was filed to size using a 3/8" diameter filing button. The four smaller 3/32" (.094) radius corner tabs were shaped to size on the belt sander using the "eyeball" method.

9344 - The Valve Disk is made from a piece of 1/8" (.125) scrap steel.
170450766 - It was machined to the outside rectangle dimension of .879" x 1.625".
163808569 - A .040"  (#60 drill) hole was drilled in each corner of the 1/8" square hole. A 3mm end mill was used to plunge the center of this square hole. The 1/8"
                     square hole was completed with pattern files..
174947266 - The 1/8" (.125) hole was drilled.
175614620 - The 1/8" (.125) hole was reamed to .126"
181830064 - All holes were drilled in the rectangular piece.
9352 - The end radii were cutout using a 1/4" 4FL end mill.
9357 - The sides were cut out using a 1/4" 4FL end mill.


Offline Larry

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Re: MEM Corliss Attempt
« Reply #92 on: July 30, 2020, 12:49:02 AM »
VALVE DISK (continued-see above)---

192721237 - All holes have been drilled and corner radii and sides have been cut out.
9404 - The large 3/16" radius end tab was filed to size using a 3/8" diameter filing button.
9408 - The 1/8" square hole was completed with pattern files.
9409 - The 1/8" square hole was checked for size using a piece of 1/8" square stock.

Offline Larry

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Re: MEM Corliss Attempt
« Reply #93 on: August 07, 2020, 11:42:56 PM »
VALVE DISK HUB - The Valve Disk Hub is made from a piece of 1" diameter 12L14 steel rod. One end was turned to 1/2" diameter x 1/2" long. This was cut off and the large end was faced to .063" thick. A thru hole was drilled to .182" (#14 drill) diameter and it was reamed to .188" (3/16) diameter. This hole was first bored .188" deep x .375" internal diameter. It was second bored .313" deep x .25" internal diameter. It was then mounted in a 1/2" diameter collet block on the mill and centered under the mill spindle using a COAX indicator. Four .128" (#30 drill) holes were drilled on a .75 PCD equally spaced per drawing. The completed part is shown in the last picture.

180930432 - The end was turned to 1/2" diameter x 1/2" long from a piece of 1" diameter 12L14 steel rod.
190745084 - This was cut off and the large end (1" diameter) was faced to .063" thick.
9416 - A thru hole was drilled to .182" (#14 drill) diameter.
170452537 - This hole was reamed to .188" (3/16) diameter.
9420 - This hole was first bored .188" deep x .375" internal diameter. It was second bored .313" deep x .25" internal diameter.
9422 - It was mounted in a 1/2" diameter collet block on the mill and centered under the spindle using a COAX indicator.
9425 - Four .128" (#30 drill) holes were drilled on a .75 PCD equally spaced per drawing.
9428 - Completed part.

Offline Don1966

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Re: MEM Corliss Attempt
« Reply #94 on: August 08, 2020, 09:12:36 PM »
Some very nice machining going on here. Nice work Larry I am just catching up on your thread.


 :cheers:
Don

Offline Larry

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Re: MEM Corliss Attempt
« Reply #95 on: August 11, 2020, 11:34:57 PM »
Thanks to Terry and Don for the kind comments - much appreciated.

VALVE DISK SPINDLE - The Valve Disk Spindle is made from a piece of 3/8" (.375) round brass rod. The first operation is to turn a section to 1/4" (.25) diameter x .663" long. The second operation is to turn a section to 3/16" (.188) diameter x .414" long. Mount in a 3/8" collet block on the mill and cut a 1/4" square x .125" long. Back to the lathe and turn the end to 1/8" (.125) diameter x .101" long. Thread the end #5-40. Cut off to approximate length and face the 3/8" (.375) diameter end to 1/8" (.125) thick. The last picture shows the completed part with a #5-40 nut.

001 - Turn a section to 1/4" (.25) diameter x .663" long.
007 - Turn the next section to 3/16" (.188) diameter x .414" long.
9436 - Mount in a 3/8" collet block on the mill and cut a 1/4" square x .125" long.
011 - On the lathe turn the end to 1/8" (.125) diameter x .101 and thread #5-40.
9441 - Cut off to approximate length.
018 - Face the 3/8" (.375) diameter end to 1/8" (.125) thick.
9446 - Completed part with a #5-40 nut.


Offline Larry

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Re: MEM Corliss Attempt
« Reply #96 on: March 04, 2021, 04:19:49 AM »
It has been awhile since I have posted. After two hospital stays with COVID (pneumonia & bronchitis) I am almost back to my normal self.

ECCENTRIC STRAP - The Eccentric Strap is made from a piece of 1 1/2" diameter brass. A disk is cut off and faced on both sides to 1/4" (.25) thick. It was then mounted in a tool clamp on the mill vise and cut in half using a .016" slitting saw. The two halves were clamped together and the tabs and oil cup surface were marked out. Mounting tabs on each half are .125" x .187". This dimension was changed so I could use #2-56 mounting screws. Oil cup surface is about .187" deep. This was added to the drawing. The eccentric rod tab is .25" x .187". This was also changed to provide more adjustment if needed. The halves were mounted in the mill vise and step milled to rough out the circumference. The halves were clamped together in the mill vise and the side mounting tabs were drilled with a #43 drill for #2-56 screws. The eccentric rod tab was drilled and tapped #5-40. The two halves were bolted together and centered in the mill vise. A pilot hole was drilled using center cutting end mills in several size steps. The center hole was then bored to .875 (7/8"). The outside surface was machined to a 1.125 (1 1/8") diameter using the pivot method. The eccentric strap was mounted on a .875 (7/8") rod in a collet and centered under the mill spindle. A spacer was used under the strap to prevent the end mill from touching the collet. I used a 3mm  4 flute end mill at 1900 rpm. I mounted a 1/8" rod in the eccentric rod tab to use as a lever. The end mill was lowered slightly below the thickness of the eccentric strap at the widest point. The work was advanced a few thousandths at a pass until the curve is cut to its full dimension. Each quarter of the strap was cut in a separate operation. This is probably not the best way to do this but will work if you are CAREFUL. Corners were filed and polished. The oil cup tab was drilled and tapped #2-56 for mounting an oil cup. An oil cup was made from a piece of 3/16" hex brass.

180605601 - Brass disk is cut in half using a .016" slitting saw.
182313496 - Disk halves.
170346823 - Halves are clamped together and tabs and oil cup surface are marked out.
9555 - Tabs are cut out.
9559 - Halves are step milled to rough out the circumference.
9563 - Halves with tabs and step milled.
9564 - Eccentric rod tab is drilled for a #5-40 thread. Note that side mounting tabs are drilled with a #43 drill to provide clearance for #2-56 screws.
9570 - Eccentric rod tab is tapped for #5-40 thread.

Offline Larry

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Re: MEM Corliss Attempt
« Reply #97 on: March 04, 2021, 04:33:18 AM »
ECCENTRIC STRAP  (Continued - see above) ---

9572 - The two halves were bolted together and centered in the mill vise. A pilot hole was drilled using center cutting end mills in several size steps.
9576 - The center hole was bored to .875 (7/8").
9582 - The outside surface was machined to a 1.125 (1 1/8") diameter using the pivot method. (See description / process above.)
9584 - Finished piece parts.
9593 - Parts assembled.

Offline Admiral_dk

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Re: MEM Corliss Attempt
« Reply #98 on: March 04, 2021, 11:59:47 AM »
Two 'trips to the Hospital' for Covid eh .... that has been a tough one on you - glad to see you back in the shop again - sure sign that you're doing better  :cheers:

Nice parts  :ThumbsUp:

Best wishes

Per

Offline Larry

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Re: MEM Corliss Attempt
« Reply #99 on: March 15, 2021, 03:20:00 AM »
Thanks Per - also my wife's sentiments exactly.

ECCENTRIC SHEAVE - The Eccentric Sheave is made from a piece of 1" round 12L14 steel rod. Mount in a 1" collet and turn center section to .875 (7/8") diameter by .25 (1/4") width using a cut-off tool taking off just a few thousandths on each pass. Set carriage stops on each side once location of width is determined. Face ends and cut off. Center 1" collet under spindle of milling machine using a piece of 1" round rod. Remove rod and mount eccentric sheave in collet. Move "Y" axis .129" off center per drawing and drill .368" hole with "U" drill (no picture). Ream this hole to .375 (3/8"). Mark center on eccentric sheave before removing from collet in preparation for drilling set screw hole. Remove eccentric sheave from collet and mount in mill vise in a vertical  position. Center .375 (3/8") hole previously marked under mill spindle using pointer and eyeball method. Drill .106" hole (#36 drill) for set screw. Tap #5-40 thread for set screw. Finished piece is shown along with assembly in Eccentric Strap.

170317029 - Turn center section to .875 (7/8") diameter by .25 (1/4") width using a cut-off tool taking off just a few thousandths on each pass.
171756488 - Face ends.
9605 - Cut off piece and face other side.
182915282 - Mount eccentric in centered collet. Move "Y" axis .129"off center per drawing and drill .368" hole with "U" drill.
9610 - Ream this hole to .375 (3/8").

Offline Larry

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Re: MEM Corliss Attempt
« Reply #100 on: March 15, 2021, 03:37:38 AM »
ECCENTRIC SHEAVE (Continued - see above) ----

182714907 - Mount eccentric in mill vise in a vertical position. Center .375 (3/8") hole previously marked under mill spindle using pointer and eyeball method. (Mark is hard
                     to see in picture.)
9618 - Drill .106" hole (#36 drill) for set screw.
9621 - Tap #5-40 thread for set screw.
194759307 - Finished eccentric sheave.
195358542 - Assembly of eccentric sheave and eccentric strap.

Offline Larry

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Re: MEM Corliss Attempt
« Reply #101 on: April 28, 2021, 09:44:57 PM »
CONNECTING ROD - The Connecting Rod is made from a piece of .625 (5/8") square 12L14 steel bar. The connecting rod is 5 1/2" long and 5/8" was added to the length making it 6 1/8" long. This provides an extra .312 (5/16") on each end for center drilling so it could be turned between centers. The excess will be milled off later. The bar is cut to approximate length and the ends are faced in the mill. The bar is chucked in a 5/8" collet in the lathe and each end is center drilled. Do not exceed a depth of .312 (5/16") when center drilling. Mark the two connecting rod holes 5" center to center. Drill holes using a "D" drill (.246). Ream these holes .25 (1/4"). Machine flat end to .5 (1/2") X .375 (3/8") X 1.125 (1 1/8") length. Mount between centers in lathe. Turn to .313" diameter for 3.750" length. Set compound rest swivel to about 1 degree and turn tapers on center section. Mill off excess .312 (5/16") on each end. Drill starting holes on fork end and mill out slot to .375 (3/8") wide. Remove radius at bottom of slot left by end mill using a slitting saw. Trim fork end with holes to .5 (1/2") wide. Do a trial assembly with crosshead. Turn .25 (1/4") radius on slotted end using pivot method. Mark angles on side of fork. Mount in mill vise using eyeball method to line up mark with top of vise jaws. Mill angle as marked.

9638 - Face ends of bar to a length of 6.125 (6 1/8") long.
9641 - Chuck the bar in a 5/8" collet in the lathe and center drill each end. Do not exceed a depth of .312 (5/16") when drilling.
9644 - Mark the two connecting rod holes 5" center to center and drill using a "D" drill (.246).
9650 - Ream these holes .25 (1/4").
9651 - Machine flat end to .5 (1/2") X .375 (3/8") X 1.125 (1 1/8").
9655 - Machine flat end to .5 (1/2") X .375 (3/8") X 1.125 (1 1/8").
9657 - Mount between centers in the lathe.
9661 - Turn to .313" diameter for 3.750" length.

Offline Larry

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Re: MEM Corliss Attempt
« Reply #102 on: April 28, 2021, 10:06:42 PM »
CONNECTING ROD (Continued-see above) ---

173719057 - Set compound rest swivel to about 1 degree and turn tapers on center section.
181658402 - Finished taper.
9667 - Mill off excess .312 (5/16") on each end.
9671 - Drill starting holes on fork end.
9673 - Mill out slot to .375 (3/8") wide.
9675 - Remove radius at bottom of slot left by end mill using a slitting saw.
9684 - Trim fork end with holes to .5 (1/2" wide.
161040361 - Trial assembly with crosshead

Offline Larry

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Re: MEM Corliss Attempt
« Reply #103 on: April 28, 2021, 10:24:27 PM »
CONNECTING ROD (Continued-see above) ---

161542551 - Finished slot.
9701 - Turn .25 (1/4") radius on slotted end using pivot method.
9703 - Finished slotted end.
9705 - Mark angles on side of fork. Mount in mill vise using eyeball method to line up mark with top of vise jaws. Mill angle as marked.
174602811 - Completed connecting rod with slotted end and tapered side.

Offline Kim

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Re: MEM Corliss Attempt
« Reply #104 on: April 28, 2021, 10:50:05 PM »
Very nice looking con rod!  :popcorn:
Kim

 

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