Air Engine

December 21st, 2015

Leah Dawkins
Ahmed Hassan
Fady Makhael
James Li

Computer Numerical Control

The CNC machine allows you to use several different
mills and drills to alter a part by cutting away material

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Air Engine Design

Bill of Materials
Item

Quantity

Price

Total Item Cost

Ball Bearing

$5.21

$20.84

Ball Bearing

$9.99

$9.99

Shaft

$1.96

$3.92

Flywheel

$16.06

$16.06

Second Flywheel

$4.03

$4.03

Joint

$5.88

$5.88

Piston Lock

$2.00

$2.00

Inlet Outlet Chamber

$15.88

$15.88

Inlet Outlet Piston

$5.47

$5.47

Engine Base

$50.37

$50.37

Main Piston Chamber

$56.64

$56.64

Total

$191.08

Allotted Time for

Construction
5 CNC Appointments
1 Lathe Appointment

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CNC (Video)

CNC (Video)

CNC (Image Still)

Image capture of CNC in

motion. (2015). Dawkins, L

Final Results

Design
Aesthetic changes
Flywheel design changed from
circular design to one with visible
gear teeth
Design yielded product with alternative
purposes and uses
Final product valid as both an air
engine and a pump

Discussion: Problems
Encountered
Tool breakage
milling tool failed
Failure likely attributed to excessive feed rate, coupled with bending
and pushing against the material

Excessive tolerances on parts ordered

Tolerances on the parts ordered were on the higher
end of the distributor specifications
Exceeded budget
Material waste
The sizes of the teeth for the main fly wheel are uneven due to
alignment issues between the HSM program the CNC machine

Discussion: Problems
Encountered
Material waste
The sizes of the teeth for the main fly wheel are uneven due to
alignment issues between the HSM program the CNC machine
Thermal expansion and cooling for aluminum occurs very quickly,
so there was difficulty in mounting the ball bearings, so epoxy was
used as a substitute

Project Takeaways
Use of the CNC machine and lathe
machine
SolidWorks and HSMWorks and their
role in the project development process
Parts of the project development
process
Determining design constraints
Budgeting time, money, and material
Ending with a final prototype product

Conclusion
We spent a great deal of time and money on our
project and overcame many complications. Weve
learned a great deal about the machining process
and how it can be used to create prototypes and
final designs. However, the limitations were
considerable enough that the project could not
reached full completion.

Questions?