Design

 Report  
Wankel  Rotary  Engine  
by  leigh  moore  L00065946  
Table of Contents
ACKNOWLEDGEMENTS  .................................................................................................................  4  
1  INTRODUCTION  ............................................................................................................................  5  
1.1  PROJECT  .......................................................................................................................................................  7  
1.2  PROJECT  TEAM  ............................................................................................................................................  9  
2.0  DESIGN  .......................................................................................................................................  10  
2.1  DESIGN  BRIEF  ............................................................................................................................................  11  
2.2  DESIGN  SPECIFICATION  ............................................................................................................................  11  
2.3  RESEARCH  OUTLINE  .................................................................................................................................  12  
2.4  THREE  CONCEPTUAL  DESIGNS  ...............................................................................................................  13  
2.5  EVALUATION  MATRIX  ...............................................................................................................................  17  
2.6  SELECTED  DESIGN  ....................................................................................................................................  18  
3.0  DESIGN  DOCUMENTATION  ..................................................................................................  19  
3.1  ASSEMBLY  DRAWING  ...............................................................................................................................  20  
3.2  EXPLODED  VIEW  .......................................................................................................................................  22  
3.3  DESIGN  ANALYSIS  AND  CALCULATIONS  ...............................................................................................  24  
Wankel  rotary  engine  geometry  .........................................................................................................  24  
Calculations  ..................................................................................................................................................  25  
Housing  design  ............................................................................................................................................  26  
Limits  and  Fits  calculations  ..................................................................................................................  27  
3.4  DESIGN  FOR  MANUFACTURING  AND  ASSEMBLY  ..................................................................................  29  
4.0  MANUFACTURE  DOCUMENTATION  ..................................................................................  30  
4.1  BILL  OF  MATERIALS  .................................................................................................................................  31  
4.2  MANUFACTURING  PROCESS  ...................................................................................................................  32  
Part  1:  Housing  ...........................................................................................................................................  33  
Part  2:  Rotor  ................................................................................................................................................  35  
Part  3:  Housing  cover  ...............................................................................................................................  37  
Part  4:  Eccentric  Shaft  .............................................................................................................................  39  
Part  5:  Eccentric  Cam  ..............................................................................................................................  41  
Part  6:  handle  ..............................................................................................................................................  44  
Part  7:  Handle  base  ...................................................................................................................................  46  
Part  8:  Gear  Hub  .........................................................................................................................................  48  
4.3  CNC  PARTS  ...............................................................................................................................................  51  
Housing  CNC  code  ......................................................................................................................................  51  
Rotor  CNC  code  ...........................................................................................................................................  53  
Housing  Front  Cover  CNC  Program  ...................................................................................................  55  
4.4  ASSEMBLY  ..................................................................................................................................................  57  
Eccentric  shaft  assembly  ........................................................................................................................  57  
Rotor  assembly  ............................................................................................................................................  58  
Gear  and  Hub  assembly  ...........................................................................................................................  59  
Handle  assembly  .........................................................................................................................................  60  
Housing  bearing  assembly  .....................................................................................................................  61  
FINAL  ASSEMBLY  .............................................................................................................................................  62  
4.5  TESTING  .....................................................................................................................................................  64  
4.6  OPTIMIZATION  AND  REWORKING  ..........................................................................................................  65  
 
 
 
 

2
5.0  CONCLUSIONS  ..........................................................................................................................  66  
5.1  DISCUSSION  ..................................................................................  ERROR!  BOOKMARK  NOT  DEFINED.  
5.2  LEARNING  OUTCOMES  .............................................................................................................................  67  
5.3  CONCLUSION  .............................................................................................................................................  68  
6.0  RECOMMENDATIONS  ............................................................................................................  69  
7.0  BIBLIOGRAPHY  AND  REFERENCES  ...................................................................................  70  
8.0  APPENDICES  ............................................................................................................................  71  
Appendix  1  Rotor  Pocket  sub-­‐program  ............................................................................................  72  
Appendix  2  Bearing  data  sheet  ............................................................................................................  81  
Appendix  3  Gear  Data  sheet  ..................................................................................................................  82  
Appendix  4  Limits  and  Fits  tolerences  ..............................................................................................  84  
Appendix  5  tapping  chart  .......................................................................................................................  89  

3
Acknowledgements
I would like to take the opportunity to thank,

Kieran O’Leary, for his help during the entire project. Kieran helped out
greatly in the design stages of this project by modeling the project in
solidworks; he also helped with his knowledge of, and accuracy on the
Milling machine. Without him, the project would not have been completed
on time with the accuracy needed for the mechanism to work porperly.

Nichola Anderson, our mechanical design and manufacturing lecturer for her
help with the CNC element of the project. Nichola also gave us a good
understanding of engineering materials, processes and design for
manufacturing along with constructive critique on how to improve our
designs. Nichola was one of our machine shop technicians and helped us
whenever needed during the manufacturing process. Nichola also helped in
the application of Microsoft Excel for this project.

Derek Thornton, our mechanical design and manufacturing lecturer, for his
help during the design phase of the project. Derek gave us help and advice
on how to model and assemble our designs on the solidworks computer
aided drawing package. This help was invaluable as it threw up some
important design features of our project that were not within the limits of
the workshops capabilities.

Charles Young, our mechanics lecturer, for his help on understanding the
forces that would be present during a motion study and how best to
orientate certain components to get a smooth motion. Charles also helped
greatly by critiquing the design that steered us to make improvements to
the design. Charles was also one of our machine shop technicians and
helped us to overcome problems during the manufacturing process.

Chris Roulston, our engineering workshop technician. Chris helped us in

many ways through the course of our project by ordering parts needed like
gears and bearings, ordering in our project specific materials and useful
advise throughout the year. Chris also helped us to debug our CNC programs
and get the CNC milling machine setup to machine our parts.

4
1 Introduction

5
This report documents the 2nd year mechanical engineering project, where a
design brief was received in which a mechanism to convert one form of
motion into another was to be designed, fabricated and tested. This brief
can be seen in section 2.1 and served as a guideline for our projects.

In semester 1, three different concepts were to be researched and

evaluated over the first few weeks. A design was chosen and research was
completed. The design stage consisted of calculations and several CAD
models. A design report was also written where we documented and
submitted our designs and plans for manufacturing of the project for
evaluation.

In second semester we were tasked with the manufacture of the project and
the documentation of the processes. The project team members would be
responsible for making parts to specifications as per design drawings. The
manufacturing of the project would commence over 9 weeks of 3 hours per
week in the workshop. In the last week the projects final assembly would
commence along with testing of the mechanism. Modifications were made
to enhance the design at this stage and then the projects were signed off on
by the project team and handed up for evaluation.

6
1.1 Project
The project chosen was the Wankel Rotary engine, an internal combustion
engine invented by a German engineer Dr. Felix Wankel.

History of the Wankel engine

Dr. Wankel began work on this engine as a 17-year-old student in 1919 after
a dream in which he drove a car with a “half-turbine half-reciprocated
engine”. In 1924 Dr. Wankel began work on his dream and was awarded a
patent for his design in 1936. Through the years of WW2, the German
Aviation Ministry who believed that once developed the rotary engine would
serve the national interest accelerated development on the rotary engine.
However it was not until 1958 with the help of the German motorcycle
manufacturer NSU, that the first successful production engine would be
finished, 39 years after Dr. Wankel had started his journey that would go on
to steer his entire life. (www.mazda.com)

The Wankel rotary engine is a demonstration of a unique design to produce

pure rotational power from an eccentric rotary motion. Dr. Wankel seen
that piston engines of the era created vibrations and mechanical stress that
negates reliability. Dr. Wankel and his colleague’s first fixed two gears
together of ratio 2:3 onto a white sheet, an external toothed gear and a
larger inner toothed gear. They then attached an arm with a pen on the
outside of the larger inner toothed gear and rotated it around the smaller
outer tooth gear creating a cocoon shaped curve. When attached to a
triangular rotor the pen would draw a shape known as a two-lobed
epitrochoid as seen in Figure 1. This would be the basic shape of the Wankel
engine right up to the present day. (www.autoevolution.com)

Figure 1

7
 Wankel engine Characteristics

The Wankel rotary engine works in the same 4 stroke cycle as a

reciprocating piston engine, with the triangular rotor completing the 4
processes of intake, compression, combustion and exhaust inside the
epitrochoid chamber as seen in Figure 2. Although both engines rely on the
expansion of an air fuel mixture, they differ in the way in which they
harness this expansion and translate it into mechanical motion. The piston
engine harnesses the expansion pressure inside a cylinder to create a force
to push a piston downwards, which is attached to the crankshaft that
translates this force into a torque to turn the output shaft in a rotary
motion. In the Wankel engine, this expansion pressure is applied to the flank
of the triangular shaped rotor to create a torque on the eccentric shaft,
which is analogous to a crankshaft in a piton engine.

The Wankel rotary engine has several advantages over the piston engine.
Firstly the Wankel rotary engine creates a power stroke for each revolution
of its eccentric shaft. Because each combustion event lasts through 90
degrees of the rotor's rotation, and the output shaft spins three revolutions
for each revolution of the rotor, each combustion event lasts through 270
degrees of the output shaft's rotation giving a two rotor Wankel engine a
comparable power delivery smoothness of a V8 piston engine. The Wankel
rotary also can achieve very high operating speeds as the rotor spins at 1/3
the speed of the eccentric shaft due to the 2:3 ratio between the internal
rotor gear and the stationary gear. With only two moving parts, the rotor
and the eccentric shaft the wankel engine is easier and cheaper to rebuild
than a comparable piston engine. The nature of the Wankel engine also
means the parts spin continuously in one direction, rather than violently
changing directions like the pistons in a piston engine. This means that a
typical two rotor Wankel engine has been seen to achieve rotational balance
comparable to a V16 piston engine without the high stresses.

Figure 2

8
1.2 Project team

I teamed up with Kieran O’Leary for this project. Both Kieran and myself
have an interest in the Wankel rotary engine and we had discussed this
project in the closing weeks of the first year of the course. Having both
been in contact with Mazda rotary cars the interest grew; therefore it was
likely that from our other concepts, the Wankel rotary engine would prevail.

Having already known a small amount about the rotary engine I tasked
myself in the design stage with the research into the complicated mechanics
and geometries that the Wankel rotary engine is known for and that also
governs its movement. This was sometimes difficult as there was limited
literature available that explained the inner workings and dimensions of
these engines, given that the Rotary Engine inventor was German and that
the only company to have continued success with it was the automotive
company Mazda who documented mostly in Japanese.

Kieran was tasked with the solidworks rendering of the project in the design
stage. Several designs were rendered until the final design was chosen and
these designs were used for the semester 1 design report. During the second
semester i designed a new rendering of the project based on new
dimensions and these designs were used in the manufacture of the project.

During manufacture both Kieran and myself made the parts together as I
had good accuracy on the manual lathe and Kieran on the manual milling
machine. The most critical parts used both a combination of lathe
machining processes and milling machine processes so the work was shared
evenly. The preparation of the CNC parts were also a shared task while I
wrote the CNC codes Kieran prepared the stock material for machining.

During assembly both Kieran and myself were involved. The high accuracy
needed during assembly called for a two-man effort to get the best results
possible and ensure correct alignment of assemblies.

9
2.0 Design

10
2.1 Design brief

To design, fabricate and test a safe mechanism that converts one

form of motion into another form of motion. The mechanism
must not be over a specified size and mass. The mechanism is
also to have at least one interference fit or clearance fit and at
least one part to be machined on the HASS CNC Lathe or Milling
machine. At least two or more of the specified materials must be
utilized in the manufacturing process and designed to make use
of machines and tools available in house.

2.2 design specification

Mechanism design requirements and constraints

• Maximum mechanism size 400!!×400!!×300!!

• Maximum mechanism mass 12!"

• At least one part to be machined on the HASS CNC lathe or

milling machine

• At least one interfearence fit or clearance fit to be

included in detailed design

• The mechanism should be manufactured from 2 or more of

the following materials: steel, aluminium, nylon, perspex.

• List of standard tooling sizes in CNC machines to be agreed

with machine room technician and lecturers before final
desing approved for fabrication by student

11
2.3 research outline
In the beginning stages of this project mainly Internet research was carried
out to find suitable mechanism to base a project on. There were very few
books available to look through on this topic as most were based n the
physics of the motion and not the motions themselves.

• Concept 1: The website used to research the radial engine was

howstuffworks.com. This site gave a very good understanding of how
the radial engine works and some of the history behind it. It aslo
showed the assembly and motion of the engine.

• Concept 2: The website mekanizmalar.com was used to research

rotary motion to rectilinear motion mechanism. This website was
referred to use by our design lecturer Derek Thornton and was full of
useful pictures and animations of various mechanism relating to the
transformation of motion.

• Comcept 3: The websites Mazda.com and howstuffworks.com were

used to research the Wankel rotary engine.

12
2.4 Three conceptual designs

13
 Concept 1: Radial engine

The radial engine was invented in the early 20th century by Jacob
Ellehammer. It was used extensively in early aircraft and its
design can still be seen in use today in small acrobatic airplanes.
The radial engine is a reciprocating type internal combustion
engine in which the cylinders point outwards from a central
crankshaft like the spokes of a wheel. These outwards cylinders
create a linear motion that is transferred into to rotary motion
through a crankshaft as seen in Figure 3. These engines at the
time had several advantages over inline piston engines like
greater cooling due to their design.

http://realitypod.com/
Figure 3

14
Concept 2: Rotational to Rectilinear motion transformer

This mechanism turned rotary motion into reciprocating linear motion. The
central rotor spins and the feet catch on the housing at the desired area to
give a displacement from left to right as seen in Figure 4 below. Possible
applications of this mechanism is on assembly lines where items are shaken
while travelling on a conveyor to separate large parts from smaller parts.

Figure 4

15
Concept 3: Wankel Rotary Engine

The Wankel Rotary engine is a unique type of internal combustion engine

using an eccentric rotary motion to create a pure rotational drive motion as
seen in Figure 5. The engine is has many advantages over regular piston
engines with its compactness, lightweight and high power output.

Figure 5

16
 2.5 evaluation matrix
The different designs were scored and compared with each other under the
criteria in the table below. This would help to pick which project we would
set out to do.

Concept 1 Concept 2 Concept 3

Rotational to
Radial rectilinear Wankel
engine mechanism rotary engine
Score Score Score
Criteria weight

Projected weight 10 10 4 7
Complexity 10 2 9 7
Feasibility 10 5 8 7
Learning 10 8 5 9
Interest 15 11 5 14
CNC part requirement 10 5 5 8
Cost of materials 10 3 8 7
Satisfies brief 10 8 10 8
Value as demonstration
model 15 9 5 13

Total score 100 61 59 80

Table 1

17
2.6 Selected design
The selected design was Concept 3: The Wankel rotary engine. This concept
scored highest in the evaluation matrix (table 1) and meets the required
criteria on both the design brief and design specification. The project team
concluded that this design was the most interesting, as it was a common
interest. This would also serve as a good educational tool on the principles
of the Wankel rotary engine that which are not always fully understood in
todays environment.

18
3.0 Design Documentation

19
3.1 Assembly drawing

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3.3 Design analysis and Calculations

Wankel rotary engine geometry

   

The Wankel rotary engine consists of two major parts, the housing and the
rotor. The housings rotor pocket is a two-lobed epitrochoid shape that is

governed by two mathematical equations. Only two key dimensions are used
$

in these formulas and through application of the

formula the epitrichoid dimensions of the housing rotor
pocket are obtained. The first dimension that is used in
the equation is the Rotor Radius or “R” value. This R 

number relates to the distance from the centre of

the rotor to its tip as seen in Figure 6. This “R”
dimension will be the same on all 3 sides. The
%

second dimension is the eccentricity or “e” value.

The “e” value is the centre distance between
circles that through complex geometries draw the
shape of a two-lobed epitrochoid seen in the
housing rotor pocket. The parametric X and Y co- Figure 6
ordinates of the epitrchoid formula are given by,
&

!   =  !  !"#  3!   +  !"#$!

!   =  !  !"#  3!   +  !  !"#  ! 81/(6627+(5:,6(63(&,),('

',0(16,216$5(,10,//,0(7(56
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%5($.6+$53
685)$&(),1,6+ ('*(6

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72/(5$1&(6
/,1($5

Where $1*8/$5

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• e is the eccentricity '5$:1 0DU

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• R is the Rotor radius
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• ! is varied from 0° − 360° (in radians) 4$ 0$7(5,$/

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The eccentricity parameter was already chosen for us because of the gears
we had purchased for the project, which for the two lobed epitrichoid
wankel engine shape have a ratio of 2:3, therefore for our project the “e”
value was the centre distance when in mesh, between the internal rotor
gear and the stationary gear as shown in Figure 7. With the calculation of
the “e” value, we now had to calculate a rotor radius “R”
value for the project. This dimension was calculated by
using the “trochoid constant K ratio”. This constant is
e the ratio between the rotor radius and eccentricity
written as K=R/e. This parameter has been seen to be
critical to the successful performance of the Wankel
rotary engine. Successful rotary engines developed by
mazda were seen to use a K ratio of around 7 so this
Figure 7 value would be used to design our project.

24
Calculations

• Calculation of eccentricity

PCD of internal rotor gear =72mm

PCD of stationary gear = 48mm

!"#  !"#$%!"#  !"#"!  !"#$ − !"#  !"#"$%&#'  !"#$

!=
2
72!! − 48!!
!= = 12!!
2

• Calculation of Rotor radius using troichoid constant K

!
!=        !"#$%&'%($)  !"  !"#$  !  !ℎ!  !"#$%&' =        ! = !  ×  !
!

! = 7  ×  12!! = 84!!

With these two dimensions two parts could now be designed, the rotor and
the eccentric shaft that would govern the motion of the mechanism.
Furthermore the dimensions needed in order to use the epitrochoid formula
for the Housing rotor pocket were now also known so the design of the
housing rotor pocket could begin.

25
Housing design

The complex geometry of the housing and its need for very high dimensional
co-ordinate accuracy meant that this part would have to be made on the
CNC milling machine. In order to get the smoothest finish possible on the
CNC machine we designed the housing rotor pocket with 360 X co-ordinates
and 360 Y co-ordinates that meant doing an X and Y calculation for every
degree between 0 and 360 degrees of a circle. Microsoft Excel was used to
save the need for 720 different calculations and it was also utilized to write
the subprogram as seen in appendix 1. The spreadsheet was then set up but
before using the equation, the degree value had to be converted into
radians for the equations to work out correctly. Below in Figure 8, is a graph
of the shape created by the excel spreadsheet when all 720 X and Y co-
ordinates are plotted on an X-Y axis graph. This shape was very much
representative of a two-lobed epitrochoid as seen in working Wankel rotary
engines.

Figure 8

26
Limits and Fits calculations

Eccentric shaft/cam tolerance

The centre 15mm journal on the eccentric shaft is to be pressed into the
eccentric cam 15mm offset hole with the interference fit H7/p6 using the
hole basis system.

ℎ!"#  15.    !!.!"#

!!.!"#  !!

!ℎ!"#  15.    !!.!"#

!!.!!!  !!

Maximum interference -0.029mm

Maximum clearance 0.000mm

Eccentric shaft/bearing tolerance

The handle side of the eccentric shaft was assigned a tolerance so that it
would press into the bearing and allow the bearing to both locate the shaft
in concentricity and allow it to rotate smoothly. A locational transition fit
H7/k6 using the hole basis system was used.

ℎ!"#  12.    !.!"#

!.!!!  !!

!ℎ!"#  12.    !.!"#

!.!!"  !!

Maximum interference -0.012mm

Maximum clearance 0.017mm

Gear hub/Gear tolerance

The gear hub shaft was assigned a tolerance to press fit into the stationary
gear centre hole. An interference fit H7/p6 using the hole basis system was
used.

ℎ!"!  20.    !.!"#

!.!!!  !!

!ℎ!"#  20.    !.!"#

!.!""  !!

Maximum interference -0.035mm

Maximum clearance -0.001mm

27
Housing/bearing tolerance

The bearing pocket that was CNC machined during the manufacturing of the
housing, had to be sized so that the bearing was a press fit. The bearing
outside diameter could not be machined so the shaft basis tolerance system
was used to size the hole. An interference f6/P7 fit from the shaft basis
system was used

ℎ!"#  32.    !!.!"#

!!.!"#  !!

!ℎ!"#  32.    !!.!!!

!!.!"#  !!

Maximum interference -0.042mm

Maximum clearance -0.001mm

Rotor/Internal gear tolerance

The rotor to be CNC machined, had to have a pocket machined so that the
gear would be pressed inside it and they would then acts as one part. This
fit had to be an interference fit so that the gear would not spin inside the
rotor. A h6/P7 shaft basis interference fit was chosen as the gears outer
diameter could not be easily changed to suit the rotor. As the Rotor was
CNC machined it was easier to use the shaft basis system and size the hole
in the CNC program.

ℎ!"#  100.    !!.!"#

!!.!"#  !!

!ℎ!"#  100.    !!.!""

!!.!!!  !!

Maximum interference -0.041mm

Maximum clearance -0.002mm

28
3.4 Design for manufacturing and assembly
Following design for manufacturing guidelines learned in class a few changes
were made to the initial design to simplify some of the critical parts and
keep closer control on part dimensions and tolerances. This guideline would
also help to streamline the manufacturing process and keep costs down.

The first design called for a 1 piece eccentric shaft. This proved to be
outside the capabilities of the workshop so a two-piece design was used
instead. This would allow us to keep a higher level of accuracy over a single
piece eccentric shaft. The eccentric cam and shaft parts would be
hydraulically pressed together to create a single eccentric shaft that would
then act as one piece. Free cutting brass was used to give a better
appearance and would provide less friction when sliding in the aluminium
bearing surface over other metals. Brass is also very easily machined and
has little bearing on tool life, brass also gives a very good surface finish that
was needed to have maximum control over the aforementioned friction.

The method of holding the stationary gear in the initial design called for the
gear to be a press fit into the prespex housing cover. Following metallurgy
study into how the steel and perspex would mate, it was deduced that the
mate would not be sufficient enough to both hold the gear in place and
restrict its radial position. A new design was rendered using solidworks in
which a gear boss would hold the stationary gear. Threaded fasteners that
would thread through the boss and into the Perspex would then restrict the
boss and gear assembly radially. Since the gear was steel we chose steel as
the material from which the gear hub would be made to give a reliable
mate.

The housing and the rotor were made from aluminium following DFMA
guidelines. Aluminium is very easily machined so this would reduce
manufacturing time and the ease of machining also meant that it has very
little impact on tool life. The housing cover was to be made out of Perspex
that was recycled from a previous mechanical engineering project to help
save costs. This design would allow the inner workings of the project to be
visible for better educational demonstration and as a viewing port for
service checks.

Following DFMA guidelines all fasteners would use standard M8, M6 and M5
sizes. A third party company would supply the gears as the workshop did not
have the facilities to manufacture gears to the specs needed in this project.
A bearing would also be supplied by a third party company and sized so that
a standard off the shelf part could be used.

29
4.0 Manufacture Documentation

30
 4.1 Bill of materials

Part Material cost

Part Material Specification Quantity
No estimate
6061 alloy
1 Housing Aluminium X1 €90.00
6061 alloy
2 Rotor Aluminium X1 €35.00
Translucent
3 Housing Cover Perspex X1 €10.00
Free Cutting
4 Eccentric Shaft Brass C36000 X1 €5.00

Free Cutting
C36000
5 Eccentric Cam Brass X1 €5.00

080M40
6 Handle Mild Steel X1 €5.00
080M40
7 Handle Base Mild Steel X1 €5.00
080M40
8 Gear Hub Mild Steel X1 €15.00
HPC Gears
Stationary #ESG1.5-32
9 Steel X1 €17.00
Gear C45/080M40/EN8

HPC Gears
#IN-1.5-48
10 Internal Gear Steel X1 €55.00
045M10

SKF Deep Groove

Housing
11 Ball bearing #6201-2Z X1 €4.00
Bearing
M8 x 25mm
12 Cap screw Steel X4 €4.00
M6 x 20mm
13 Grub screw Steel X4 €3.00
M5 x 12mm
14 Grub screw Steel X1 €1.00
15 Countersunk
steel M8 x 20mm X1 €1.00
screw
Total 21 €255.00

31
4.2 Manufacturing Process

32
 Part 1: Housing

Aluminium
250mm x 200mm x
Stock material
45mm
Billet stock

Estimated manufacturing time 6 hours

Manual Milling machine

Machines used
CNC milling machine

Manual mill tools 50mm fly cutter

10mm slot drill

Tooling used CNC mill tools
7mm drill bit

Hand tools M8 tap

Procedure

• Insert stock material into vice of manual milling machine

• Square off bottom edge with 50mm fly cutter
• Remove from vice
• Stock material taken to CNC milling machine
• Clamped to machine bed on top of waste material
• Machine axis zero’d
• Tool radius and length compensations set
• CNC program loaded onto machine
• CNC cycle start
1. Rotor pocket cycle
2. Bearing Pocket cycle
3. 7mm holes cycle
4. Profile cut cycle
• Remove from CNC milling machine
• Tap holes M8 x 4
• Part complete

33
      


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 Part 2: Rotor

Aluminium
150mm x 150mm x
Stock material
300mm
Billet square stock

Estimated manufacturing time 4 hours

CNC milling machine

Machines used
Ban Saw

Manual lathe

50 mm fly cutter

CNC mill tools 8mm slot drill

Tooling used

Tungsten Carbide
Manual Lathe
cutting insert

Procedure

• Insert stock material into CNC milling machine Vice

• Top surface manually sqaured with 50mm fly cutter
• Machine axis zero’d
• Tool radius and length compensations set
• CNC program loaded onto machine
• CNC cycle start
1. Internal gear pocket cycle
2. Eccentric cam Pocket cycle
3. Profile cut cycle
• Remove from CNC milling Machine
• Place stock in Ban Saw
• Rotor released from stock material
• Rotor taken to manual lathe
• Rear Face of Rotor machined down to final width
• Part complete

35
      


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 Part 3: Housing cover

Perspex
250mm x 200mm x
Stock material Sheet stock
10mm

Estimated manufacturing time 3 hours

Machines used
CNC milling machine

HSS slot drill 10mm

CNC mill tools
Tooling used HSS drill bit 9mm

HSS drill bit 5.5mm

Procedure

• Insert stock material into CNC milling machine Vice

• Clamped to machine bed on top of waste material
• Machine axis zero’d
• Tool radius and length compensations set
• CNC program loaded onto machine
• CNC cycle start
1. Center pocket cycle
2. Gear hub 5.5mm holes cycle
3. Housing 9mm holes cycle
4. Profile cut cycle
• Remove from CNC milling machine
• Part complete

37
      

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 Part 4: Eccentric Shaft

Brass
Stock material ∅30mm x 120mm
Round Bar stock

Estimated manufacturing time 3 hours

Ban Saw
Machines used
Manual Lathe

Tungsten Carbide
cutting insert

HSS Centre drill

Tooling used Manual lathe tools
Tailstock Centre

HSS Parting off tool

3mm

Procedure

• Material cut to length on Ban saw

• Stock material inserted into manual lathe
• Face off
• Centre drill face
• Insert centre into tailstock
• Use centre in tailstock to support material via centre drilled hole
• Turn entire stock down to 15mm tolerence as specified
• Turn down each side down to specification using 3mm part off tool
• Part off
• Part removed from manual lathe
• Flat edge created using smooth hand file
• Part complete

39
      

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 Part 5: Eccentric Cam

Free Cutting Brass

Stock material ∅50mm x 50mm
Round Bar stock

Estimated manufacturing time 3 hours

Ban Saw
Machines used
Manual lathe

Manual Milling machine

Tungsten Carbide
cutting insert

Manual lathe tools HSS Centre drill

HSS Parting off tool

3mm
Tooling used
HSS Centre drill

V clamps
Manual mill tools
HSS drill bit 14.5

HSS Reamer 15mm

41
Procedure

• Material cut to length on Ban saw

• Stock material inserted into manual lathe
• Face off
• Centre drill face
• Turn down to tolerence down to 49.5mm tolerence as specified
• Part off
• Part clamped into manual milling machine using V-Blocks
• Centre drill inserted into mill
• Centre of part located using centre drill
• Digital co-ordinate Readout zero’d
• Bed offset 12mm and locked
• Part centre drilled
• Tool changed to HSS drill bit 14.5
• 14.5mm hole drilled through part
• Tool changed to 15mm HSS reamer
• Reamer used to create 15mm tolerence hole through part
• Part complete

42
      


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 Part 6: handle

Mild steel
Stock material ∅30mm x 100mm
Round bar stock

Estimated manufacturing time 1 hour

Ban Saw
Machines used
Manual lathe

Tungsten Carbide
cutting insert

HSS Centre drill

Manual lathe tools
HSS drill bit 7mm
Tooling used
HSS Parting off tool
3mm

Hand tools M8 tap

Procedure

• Material cut to length on Ban saw

• Stock material inserted into manual lathe
• Face off
• Centre drill face
• Turn down to 20mm
• 7mm drill bit inserted into tailstock
• Coolant on
• 7mm hole drilled to specified depth
• Part off
• Coolent off
• Tap hole M8
• Part complete

44
      

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 Part 7: Handle base

Mild steel
100mm x 25mm x
Stock material
10mm
Flat plate stock

Estimated manufacturing time 2 hours

Ban Saw
Machines used
Manual Milling machine

50mm fly cutter

HSS drill bit 4mm

Tooling used Manual mill tools
HSS drill bit 9mm

HSS drill bit 12mm

Procedure

• Material cut to length on Ban saw

• Stock inserted into manual milling machine
• Ends squared off and machined down to specified length
• Centreline of part found by touching off part
• Digital co-ordinate Readout zero’d
• HSS 12mm drill bit inserted into mill
• Bed moved to correct location
• 12mm shaft hole drilled using coolant
• HSS 9mm drill bit inserted into mill
• Bed moved to correct location
• 9mm Handle hole drilled using coolant
• Part flipped onto side
• HSS 4mm drill bit inserted into mill
• 4mm stop screw hole drilled using coolant
• Remove part from vice
• Deburr edges
• Tap stop hole M5

46
      

$ $
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 Part 8: Gear Hub

Mild steel
∅60mm x 70mm
Stock material
Round bar stock

Estimated manufacturing time 4 hours

Manual Lathe
Machines used
Manual Milling machine

Tungsten Carbide
cutting insert

HSS Centre drill

HSS drill bit 7mm

Manual lathe tools HSS drill bit 11.5mm

HSS Reamer 12.5mm

HSS Parting off tool

Tooling used 3mm

Morse taper

V-Blocks

Manual mill tools 12mm Silver Steel

HSS drill bit 5.5mm

Hand tools M6 tap

48
Procedure

• Material cut to length on Ban saw

• Stock inserted into manual lathe
• Face off
• Turn down stock to 60mm
• Centre drill face
• HSS 7mm drill bit bitted to tailstock
• Coolant on
• Stock centre drilled 7mm
• HSS 11.5 drill bit inserted into tailstock
• Stock centre drilled 11.5mm
• 12.5mm HSS Reamer fitted into tailstock using appropriate morse
taper
• Stock centre reamed to tolerence
• Turn down front shoulder to tolerence
• Part off
• Insert part into milling machine vice using V-Blocks
• 12mm silver steel bar inserted into mill
• centre of part located
• Digital co-ordinate Readout zero’d
• HSS 5.5mm drill bit inserted into miling machine
• Bed moved to correct postion
• 5.5mm hold drilled at all 4 specified locations
• part removed from milling machine
• holes tapped M6
• part complete

49
      

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 4.3 CNC Parts

Housing CNC code

The Housing was easily the most time consuming part to be CNC coded in
this project. The main Housing code was not difficult to write but the
complex geometry for the epitrichoid Rotor pocket, which was calculated in
excel, had to be used as a separate program and called up in the main code
using M98 subprogram call up (refer to appendix A), to stop the main code
from becoming unmanageably long. The Sub Code consisted of the 360 X and
360 Y co-ordinates that would be called up by the Main code to trace the
epitrochoid shape. It also consisted of the straight-line commands that
would remove the material from the middle of the pocket after the Rotor
pocket was cut. The straight-line command and the resulting co-ordinates
were done by hand, as a cycle G code to remove the material was not
available to meet our needs. The material was specially ordered in to create
this part so there was no room for error in the code so constant safety
checks were carried out before and during manufacturing.

Figure 9 below shows the method in which the stock material was held in
the machine and the position of the floating zero point on the bottom left
corner of the stock material. The dimensions of the material were measured
so we could then interpolate the center of the material by touching off the
edges of the stock material that were squared off on the manual milling
machine. The code for this part also had to carefully take into account the
Z-axis heights as the tool moved around the part so as not to crash into the
clamps.
   
CLAMP

CLAMP


$

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CLAMP

&
CLAMP

51


Figure 9
81/(6627+(5:,6(63(&,),(' ),1,6+ '(%85$1'
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%; G00 G90 G53 Z0; G01 Z-17.5;
(ROTOR HOUSING CODE); ; M97 P800;
(SAFETY START LINE); (DRILLING M8 HOLES); G01 Z-20.;
G90 G00 G40 G80 G98 G17 G21; ; M97 P800;
(G54 WORK OFFSET); G53 Z0 M05; G01 Z-22.5;
G90 G00 G54; M01; M97 P800;
; T2 M06 (7MM DRILL); G01 Z-25.;
(ROTOR POCKET PROCESS); G00 G43 H04 Z50.; M97 P800;
G53 Z0 M05; M08; G01 Z-27.5;
M01; G00 G54 X0 Y0 Z5.; M97 P800;
T1 M06 (10MM SLOT DRILL); ; G01 Z-30.;
G00 G43 H01 Z50.; G00 X0 Y80.; M97 P800;
M08; G01 Z-30. F50; G01 Z-32.5;
G00 X0 Y5; Z10.; G01 Z50; M97 P800;
G01 Z-2.5; G00 X106. Y0; G01 Z-35.;
M98 O00037; G00 Z5.; M97 P800;
G01 Z-5.; G01 Z-30 F50; G01 Z-37.5;
M98 O00037; G00 Z50.; M97 P800;
G01 Z-7.5; G00 X0 Y-80; G01 Z-40.;
M98 O00037; G00 Z5.; M97 P800;
G01 Z-10.; G01 Z-30 F50; G01 Z-42.5;
M98 O00037; G00 Z50.; M97 P800;
G01 Z-12.5; G00 X-106. Y0; G01 Z-46.;
M98 O00037; G00 Z5.; M97 P800;
G01 Z-15.; G01 Z-30; G00 Z50. M09;
M98 O00037; G00 Z50; G00 G40 X0 Y0 ;
G01 Z-17.5; G00 X0 Y0; M30;
M98 O00037; ; ;
G01 Z-20.; (DRILLING FINISHED); (PROFILE CUT FINISHED);
M98 O00037; ; ;
G01 Z-22.5; G53 Z0 M05; (BLOCK CALL UP FOR PROFILE
M98 O00037; M01; CUT CO-ORDINATES)
G01 Z-25.; ; ;
M98 O00037; (PROFILE CUT PROCESS);
N800;
G01 Z-27.5; ;
M98 O00037; T1 M06 (10MM SLOT DRILL);
G00 X125. Y-95.;
G01 Z-30.; G00 G43 H02 Z50.; G01 G41 X116. Y-88.;
M98 O00037; M08; G01 X-28. Y-88.;
G01 Z-32.5; ; G02 X-28. Y88. R88.;
M98 O00037; G00 G54 X0 Y0 Z50.; G01 X116. Y88.;
G01 Z-35.; G00 X125. Y -95.; G00 Z50.;
M98 O00037; G00 Z5.; G00 X125. Y -95.;
; G01 Z-2.5; G00 Z5.;
(CENTER POCKET FINISHED); M97 P800; M99;
; G01 Z-5.; %
(BEARING POCKET PROCESS); M97 P800;
G00 Z20; G01 Z-7.5;
G00 X0 Y0; M97 P800;
G00 Z-35.; G01 Z-10.;
G13 G91 Z-2.6 I5 K15.981 Q5 M97 P800;
D02 F100 L4; G01 Z-12.5;
; M97 P800;
(BEARING POCKET FINISHED); G01 Z-15.;
; M97 P800;

52
 Rotor CNC code

The unique shape of the Rotor and the precision needed meant that this
part was going to be CNC machined. The code for the rotor was relatively
simple to construct. The code consists of three main parts, the pocket for
the internal gear that needed to be a press fit, the eccentric pocket for the
eccentric shaft to allow for a smooth running location fit and the outer
profile which had to be very accurate to allow it to spin inside the rotor
housing. The code makes uses of a block call up function were the profile
'

&

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cuts co-ordinates were called up using the M97 code. As seen in the code
this called up the block number N800 that had the co-ordinates of the
profile geometry. This method was used to avoid repetition as the depth of


the part lead to 9 passes of the tool in total around the profile shape.

Figure 10 below shows the method in which the stock material was held in
the machine and the position of the floating zero point on the top right
corner of the stock material, as we knew the dimensions of the material we
could interpolate the center of the material and make the part quite easily.


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53

%
(ROTOR CODE); M97 P800;
; G01 Z-25 F50;
(SAFETY START LINE); M97 P800;
G90 G00 G40 G80 G98 G17 G21; G01 Z-30 F50;
; M97 P800;
(G54 WORK OFFSET); G01 Z-35 F50;
G90 G00 G54; M97 P800;
; G01 Z-40 F50;
N1 (CENTER POCKET); M97 P800;
; G01 Z-45 F50;
T4 M06; M97 P800;
G90 G54 G00 X-10 Y10; ;
S2000 M03; (PROFILE CUT FINISHED);
G43 H04 Z5 M08; ;
G41 G01 X0 Y0 Z1; (BLOCK CALL UP);
G01 X75 Y-86 Z1; ;
G01 Z0; N800;
G13 G91 Z-2.5 I5 K50.01 Q8.5 D04 G00 G41 X75 Y-2;
F200 L6; G01 Z0;
G13 G91 Z-2.5 I5 K24.775 Q8.5 D04 G02 X147.746 Y-128 R170 F200;
F200 L10; G02 X2.254 Y-128 R170;
; G02 X75 Y-2 R170;
(POCKETS FINISHED); M99;
;
N2 (PROFILE CUT);
;
G00 G90 Z5;
G01 Z-5 F50;
M97 P800;
G01 Z-10 F50;
M97 P800;
G01 Z-15 F50;
M97 P800;
G01 Z-20 F50;

54
 Housing Front Cover CNC Program

The front cover for the housing was originally planed to be a part that would
be made on the manual machines but as the project developed and our
understanding of the accuracy needed for this part it was chosen as another
part in which to be CNC machined on the milling machine. The nature of the
concentricity of the project meant that the centre pocket had to be firstly
machined precisely on the centre and that the pocket needed a very tight
tolerance for the gear to locate as accurately as possible. The code consists
of 4 different processes including, as mentioned the centre pocket, 4
accurately drilled M8 holes, another 4 accurately drilled holes 5.5mm and
the profile cut that would perfectly match the profile of the housing itself
to give a seamless fit.

Figure 11 below shows the method in which the stock material was held in
the machine and the position of the floating zero point on the bottom left
corner of the stock material, as we knew the dimensions of the material we
could again interpolate the center of the material and make the part quite
easily. The code for this part also had to take into account the Z axis
heights as it moved around the part so as not to crash the tool into the
clamps.

    
CLAMP

CLAMP
CLAMP

CLAMP

Figure 11
55
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% N3 (INSIDE M6 HUB HOLES);
O00035; G53 Z0 M05;
(ROTOR HOUSING COVER CODE); M01;
; T6 M06 (5.5MM DRILL);
(SAFETY START LINE); G01 Z-12.;
G90 G00 G40 G80 G98 G17 G21; G00 Z50.;
; G00 G53 Z0;
(G54 WORK OFFSET); ;
G90 G00 G54; ;
; N3 (INSIDE M6 HUB HOLES);
; G53 Z0 M05;
N1 (CENTER POCKET); M01;
G53 Z0 M05; T6 M06 (5.5MM DRILL);
M01; G00 G43 H06 Z50.;
T1 M06 (10MM SLOT DRILL); M08;
S2500 M03; G00 X0. Y25.;
G00 G43 H01 Z50.; G00 Z5.;
M08; G01 Z-12. F80.;
G00 X0. Y0.; G01 Z5.;
G01 Z10. F400.; G00 X25. Y0.;
G01 Z0 F100.; G01 Z-12.;
G13 G91 X0. Y0. Z-2.6 I5. K20.003 Q6.5 D01 G01 Z5.;
F150. L4; G00 X0. Y-25.;
G00 G90 G53 Z0; G01 Z-12.;
; G01 Z5.;
N2 (OUTSIDE M8 HOUSING HOLES); G00 X-25. Y0.;
G53 Z0 M05; G01 Z-12.;
M01; G01 Z5.;
T2 M06 (9MM DRILL); G00 G53 Z0;
S1500 M03; ;
G00 G43 H02 Z50.; N4 (PROFILE CUT);
M08; G53 Z0 M05;
G00 G54 X0. Y0.; M01;
G01 Z5. F400.; T1 M06 (10MM SLOT DRILL);
G00 X0. Y80.; G00 G43 H01 Z50.;
G01 Z-12. F50.; M08;
G00 Z50.; G00 X125. Y-95.;
G00 X106. Y0.; G01 Z6.;
G00 Z5.; G01 G41 X116. Y-88.;
G01 Z-12.; G01 X-28. Y-88.;
G00 Z50.; G02 X-28. Y88. R88.;
G00 X0. Y-80.; G01 X116. Y88.;
G00 Z5.; G00 Z50.:
G01 Z-12.; G00 X116. Y-88.;
G00 Z50.; G00 Z3.;
G00 X-106. Y0.; G01 Z-12.5;
G00 Z5.; G01 X-28. Y-88.;
; G02 X-28. Y88. R88.;
G01 Z-12.; G01 X116. Y88.;
G00 Z50.; G00 G53 Z0;
G00 G53 Z0; G00 G40 X0 Y0;
; ;
M30;
%

56
4.4 Assembly

Eccentric shaft assembly

The first assembly is to join the eccentric shaft with the eccentric cam. This
was done with the hydraulic press as shown. The eccentric cam was set onto
the press and the shaft was fed into the hole. Pressure was applied until the
shaft centre shoulder filled the centre hole on the eccentric cam and was
seen to be flush on both sides.

57
Rotor assembly

The second assembly is the mating of the Rotor and the internal Gear. This
is done using the hydraulic press as shown below. The gear is mounted onto
the Rotor and pressed into place with the hydraulic press. Pressure is to be
applied until the gear is seated flush with the rotors front face or until the
hydraulic pressure gauge was seen to rise in load.

58
Gear and Hub assembly

The third assembly is the mating off the Gear Hub, stationary gear and the
housing front cover. The design and successful motion of the project would
hang on these parts if they were not made within the correct tolerances.
Once pressed together these parts would act as a single part. The rotor and
eccentric shaft are set into the housing and the stationary gear fitted into
position located by the eccentric shaft. The stationary gear is meshed into
position with the internal gear in the rotor in the correct orientation. The
cover is then placed over the top of the housing with the centre pocket
lined up and set over the boss on the front of the stationary gear. 4 dowels
of silver steel to be cut and used to align the holes in the front cover with
the holes in the gear hub. The gear hub is then placed on top for its shaft to
be pressed into the centre hole of the stationary gear. A hydraulic press is
then used to press the gear hub shaft down into the stationary gear. Lastly
the 4 grub screw fasteners (Part 13) are used to stop the gear hub and gear
assembly from rotating, they are threaded into the face of the hub and into
the front cover.

59
Handle assembly

The fourth assembly is the assembly of the handle used to turn the
mechanism. The single countersunk screw M8 (part 15) is then used to
attach the handle to the handle base via the 9mm hole. Lastly use the cap
screw M5 (part 14) and screw into the shaft side. This will be used to hold
the handle in radial position on the shaft once the full assembly is finished.

60
Housing bearing assembly

The fifth assembly involves the pressing of the bearing into the housing. The
housing is to be laid on a flat surface and the ball bearing to be place inside
the hole and taped into place until flush with both front and rear surface of
the housing.

61
Final assembly

Below are the steps for final assembly of the Wankel rotary engine

Step 1: Thoroughly clean and oil all parts

Step 2: Push the 12mm flat edge side eccentric shaft through the bearing in
housing until eccentric cam face is flush with housing face.

Step 3: Lower the rotor assembly into the Housing in the correct orientation
so that the eccentric shaft cam is a smooth fit with the eccentric
cam pocket in the rotor. Note, there is only one way in which the
rotor will fit into the housing.

Step 4: Using the front cover, gear and gear hub assembly, place the cover
on top of the housing so that the gears mesh. Secure front cover to
housing using the 4 M8 cap screws (part 12).

Step 5: Attach handle to the eccentric shaft that is protruding from rear
face of housing. Offset the handle 180 from the direction of the
eccentric shaft cam maximum lift for better motion. Tighten down
M5 grub screw to lock handles radial position on the eccentric shaft.

Assembly complete

62
63
4.5 Testing
Testing began with checking the dimensional accuracy of the crucial parts
that allow the mechanism to function. These parts had to be as accurate as
possible and in the manufacturing, accuracy was given top priority. The
nature of the Wankel rotary engine calls for perfect concentricity between
these parts and miss-alignment would lead to poor motion.

Part tested Comments

Housing • The housing rotor pocket depth was measured using a
drop gauge and found to be within specification.
• The inner periphery of the Rotor pocket was also
checked for smoothness and found to be a satisfactory
surface finish.
• The Rotor pocket major X and Y co-ordinates were also
measured and seen to be within specification.
• The bearing pocket dimension was also check and
found to be within tolerance.
• The position of the holes were checked and seen to be
within specification and the fasteners were threaded
into their respective hole and seen to run smoothly
and tighten as specified.

Rotor • The rotor was test fitted into the housing after
machining and found to not fit due to the sharp edges
on the points of the rotor.
• The rotor was also measured with a drop gauge and
found to be varying in width dimension across its cross
section.
• The Gear pocket and eccentric journal pocket were
measured and found to be within their respective
tolerances.

Eccentric shaft • The eccentric shafts eccentricity was measured using a

drop gauge and seen to be within specification.
• The roundness of the centre journal was checked using
a dial test indicator; the part was seen to have bulged
out in spots by as much as 0.03mm due to the V-Block
clamping method in the milling machine.
• Both ends of the shafts were meaured and found to be
within their respective tolerences.

64
4.6 Optimization and reworking

Part Modifications carried out

• The 3 rotor tips were given a

1mm radius using emery paper
and lubrication.

• The Internal gear pressed into

the rotor was also seen to be
sitting proud of the rotor by
0.02mm
Rotor
• The rotor assembly was placed
back onto the lathe were it
would be faced off to correct
its varying cross sectional
width and also to correct the
face of the gear to bring both
parts flush with one another.

• The eccentric shaft journal

high spots and scrathes were
Eccentric shaft removed using emery paper
and lubrication.

65
5.0 conclusions

66
5.2 Learning outcomes
During both the design and manufacturing of this project several problems
were encountered and lessons learned that would not be passed onto
projects in the future. Learning outcomes include,

• The importance of DFMA in the design phase of the project. Aspects

such as suitability and availability of materials for their respective
applications, research and standardisation of fasteners to be used
and the time and cost implications of setting tolerences and surface
finishes onto parts.

• The utilization of the solidworks CAD software but keeping to realistic

boudaries due to workshop and time restrictions.

• The use of the CNC machines in the early stages of the design. The
CNC codes for this project were complicated and took up a large
portion of design time because a lot of independent learning and
research was done to get the dimensions and codes compiled.

• The importance of time management when manufacturing parts.

When entering the workshop for our allocated time slot a
comprehensive process plan for the chosen part to be made is
essential in order make use of the machining processes effectively.

67
5.3 Conclusion
As part of our 2nd year we were tasked with the design and manufacture of a
mechanism that converts one for of motion into another. Three concepts
were chosen and researched before a final design was chosen to be our
project, the project team decided on the Wankel rotary engine.

• The Wankel rotary engine fulfills the design brief as its converts
eccentric rotating motion into purely rotational motion.

• The mechanism was designed within the restrictions of the design

specification including physical dimensions and mass.

• DFMA guidelines were followed during the design of the project to

streamline the manufacturing and assembly processes.

• Various materials were used during manufacturing ranging from

aluminium, brass, Perspex and mild steel as per design specification.

• The design specification called for at least one part of the project to
be CNC machined which we met by making 3 highly complex parts by
means of the CNC milling machine.

• The design specification also called for at least one tolerence fit
between parts, our design had 5 different limits and fits using both
the hole and shaft basis system.

68
6.0 Recommendations
The project was successfully assembled and worked as it should, however
during testing a few dimensions were seen to need slight reworking to
optimize the design. Changes that I would recommend would be,

• During the CNC milling of the Rotor a 1mm radius would be

programmed onto the rotor tips.

• Careful attention to be payed to tool length compensations in the

CNC machine as these may have caused the Rotor depth to be out of
depth tolerence if incorrect.

• Further research could have been carried out and specialist

equipment bought to make the Eccentric shaft as a single piece. This
would have negated the need for reworking of the eccentric journal
due to the problems with clamping the eccnetric cam as mentioned.

69
7.0 Bibliography and references
Conceptual design references

http://realitypod.com/2010/08/complex-stuff-explained-in-simple-
animations/

http://kmoddl.library.cornell.edu/model.php?m=472

http://www.autoguide.com/auto-news/tag/rotary-engine

Weston, Kenneth C 1992. Energy conversion, West Publishing Company,

College & School Division.

Yamamoto, K 1971. Rotary Engine, Toyo Kogyo Co ltd, Tokyo.

Yamamoto, K 1971. Rotary Engine, Toyo Kogyo Co ltd, Tokyo.

70
8.0 Appendices

71
Appendix 1 Rotor Pocket sub-program

%
;
(SUB PROGRAM FOR ROTOR HOUSING);
;
(CO-ORDINATES OF ROTOR POCKET OUTLINE);
;
G01 G41 X0 Y-5;
G01 X96. Y0;
G01 X95.971 Y2.094;
G01 X95.883 Y4.186;
G01 X95.737 Y6.273;
G01 X95.533 Y8.354;
G01 X95.271 Y10.427;
G01 X94.953 Y12.489;
G01 X94.577 Y14.537;
G01 X94.145 Y16.571;
G01 X93.658 Y18.588;
G01 X93.116 Y20.586;
G01 X92.521 Y22.564;
G01 X91.873 Y24.518;
G01 X91.173 Y26.448;
G01 X90.423 Y28.351;
G01 X89.623 Y30.226;
G01 X88.776 Y32.071;
G01 X87.881 Y33.885;
G01 X86.942 Y35.666;
G01 X85.959 Y37.412;
G01 X84.934 Y39.122;
G01 X83.869 Y40.795;
G01 X82.764 Y42.429;
G01 X81.623 Y44.024;
G01 X80.446 Y45.579;
G01 X79.236 Y47.091;
G01 X77.994 Y48.561;
G01 X76.722 Y49.987;
G01 X75.422 Y51.370;
G01 X74.096 Y52.708;
G01 X72.746 Y54.000;
G01 X71.374 Y55.247;
G01 X69.982 Y56.447;
G01 X68.571 Y57.602;
G01 X67.144 Y58.710;
G01 X65.703 Y59.772;
G01 X64.249 Y60.787;
G01 X62.785 Y61.755;
G01 X61.312 Y62.678;
G01 X59.832 Y63.555;

72
G01 X58.348 Y64.386;
G01 X56.860 Y65.173;
G01 X55.371 Y65.915;
G01 X53.882 Y66.614;
G01 X52.395 Y67.269;
G01 X50.912 Y67.882;
G01 X49.434 Y68.454;
G01 X47.962 Y68.986;
G01 X46.499 Y69.478;
G01 X45.045 Y69.931;
G01 X43.602 Y70.348;
G01 X42.171 Y70.728;
G01 X40.753 Y71.074;
G01 X39.349 Y71.386;
G01 X37.961 Y71.666;
G01 X36.589 Y71.915;
G01 X35.234 Y72.134;
G01 X33.897 Y72.326;
G01 X32.579 Y72.490;
G01 X31.280 Y72.630;
G01 X30.000 Y72.746;
G01 X28.740 Y72.840;
G01 X27.501 Y72.913;
G01 X26.283 Y72.967;
G01 X25.085 Y73.004;
G01 X23.909 Y73.024;
G01 X22.753 Y73.030;
G01 X21.618 Y73.022;
G01 X20.504 Y73.003;
G01 X19.411 Y72.973;
G01 X18.337 Y72.934;
G01 X17.284 Y72.888;
G01 X16.249 Y72.835;
G01 X15.233 Y72.778;
G01 X14.236 Y72.716;
G01 X13.256 Y72.652;
G01 X12.292 Y72.587;
G01 X11.344 Y72.521;
G01 X10.411 Y72.456;
G01 X9.492 Y72.393;
G01 X8.586 Y72.332;
G01 X7.693 Y72.274;
G01 X6.810 Y72.220;
G01 X5.937 Y72.171;
G01 X5.072 Y72.127;
G01 X4.215 Y72.089;
G01 X3.365 Y72.058;
G01 X2.519 Y72.033;
G01 X1.677 Y72.015;
G01 X0.838 Y72.004;
73
G01 X0 Y72.0;
G01 X-0.838 Y72.004;
G01 X-1.677 Y72.015;
G01 X-2.519 Y72.033;
G01 X-3.365 Y72.058;
G01 X-4.215 Y72.089;
G01 X-5.072 Y72.127;
G01 X-5.937 Y72.171;
G01 X-6.810 Y72.220;
G01 X-7.693 Y72.274;
G01 X-8.586 Y72.332;
G01 X-9.492 Y72.393;
G01 X-10.411 Y72.456;
G01 X-11.344 Y72.521;
G01 X-12.292 Y72.587;
G01 X-13.256 Y72.652;
G01 X-14.236 Y72.716;
G01 X-15.233 Y72.778;
G01 X-16.249 Y72.835;
G01 X-17.284 Y72.888;
G01 X-18.337 Y72.934;
G01 X-19.411 Y72.973;
G01 X-20.504 Y73.003;
G01 X-21.618 Y73.022;
G01 X-22.753 Y73.030;
G01 X-23.909 Y73.024;
G01 X-25.085 Y73.004;
G01 X-26.283 Y72.967;
G01 X-27.501 Y72.913;
G01 X-28.740 Y72.840;
G01 X-30.000 Y72.746;
G01 X-31.280 Y72.630;
G01 X-32.579 Y72.490;
G01 X-33.897 Y72.326;
G01 X-35.234 Y72.134;
G01 X-36.589 Y71.915;
G01 X-37.961 Y71.666;
G01 X-39.349 Y71.386;
G01 X-40.753 Y71.074;
G01 X-42.171 Y70.728;
G01 X-43.602 Y70.348;
G01 X-45.045 Y69.931;
G01 X-46.499 Y69.478;
G01 X-47.962 Y68.986;
G01 X-49.434 Y68.454;
G01 X-50.912 Y67.882;
G01 X-52.395 Y67.269;
G01 X-53.882 Y66.614;
G01 X-55.371 Y65.915;
G01 X-56.860 Y65.173;
74
G01 X-58.348 Y64.386;
G01 X-59.832 Y63.555;
G01 X-61.312 Y62.678;
G01 X-62.785 Y61.755;
G01 X-64.249 Y60.787;
G01 X-65.703 Y59.772;
G01 X-67.144 Y58.710;
G01 X-68.571 Y57.602;
G01 X-69.982 Y56.447;
G01 X-71.374 Y55.247;
G01 X-72.746 Y54.000;
G01 X-74.096 Y52.708;
G01 X-75.422 Y51.370;
G01 X-76.722 Y49.987;
G01 X-77.994 Y48.561;
G01 X-79.236 Y47.091;
G01 X-80.446 Y45.579;
G01 X-81.623 Y44.024;
G01 X-82.764 Y42.429;
G01 X-83.869 Y40.795;
G01 X-84.934 Y39.122;
G01 X-85.959 Y37.412;
G01 X-86.942 Y35.666;
G01 X-87.881 Y33.885;
G01 X-88.776 Y32.071;
G01 X-89.623 Y30.226;
G01 X-90.423 Y28.351;
G01 X-91.173 Y26.448;
G01 X-91.873 Y24.518;
G01 X-92.521 Y22.564;
G01 X-93.116 Y20.586;
G01 X-93.658 Y18.588;
G01 X-94.145 Y16.571;
G01 X-94.577 Y14.537;
G01 X-94.953 Y12.489;
G01 X-95.271 Y10.427;
G01 X-95.533 Y8.354;
G01 X-95.737 Y6.273;
G01 X-95.883 Y4.186;
G01 X-95.971 Y2.094;
G01 X-96. Y0;
G01 X-95.971 Y-2.094;
G01 X-95.883 Y-4.186;
G01 X-95.737 Y-6.273;
G01 X-95.533 Y-8.354;
G01 X-95.271 Y-10.427;
G01 X-94.953 Y-12.489;
G01 X-94.577 Y-14.537;
G01 X-94.145 Y-16.571;
G01 X-93.658 Y-18.588;
75
G01 X-93.116 Y-20.586;
G01 X-92.521 Y-22.564;
G01 X-91.873 Y-24.518;
G01 X-91.173 Y-26.448;
G01 X-90.423 Y-28.351;
G01 X-89.623 Y-30.226;
G01 X-88.776 Y-32.071;
G01 X-87.881 Y-33.885;
G01 X-86.942 Y-35.666;
G01 X-85.959 Y-37.412;
G01 X-84.934 Y-39.122;
G01 X-83.869 Y-40.795;
G01 X-82.764 Y-42.429;
G01 X-81.623 Y-44.024;
G01 X-80.446 Y-45.579;
G01 X-79.236 Y-47.091;
G01 X-77.994 Y-48.561;
G01 X-76.722 Y-49.987;
G01 X-75.422 Y-51.370;
G01 X-74.096 Y-52.708;
G01 X-72.746 Y-54.000;
G01 X-71.374 Y-55.247;
G01 X-69.982 Y-56.447;
G01 X-68.571 Y-57.602;
G01 X-67.144 Y-58.710;
G01 X-65.703 Y-59.772;
G01 X-64.249 Y-60.787;
G01 X-62.785 Y-61.755;
G01 X-61.312 Y-62.678;
G01 X-59.832 Y-63.555;
G01 X-58.348 Y-64.386;
G01 X-56.860 Y-65.173;
G01 X-55.371 Y-65.915;
G01 X-53.882 Y-66.614;
G01 X-52.395 Y-67.269;
G01 X-50.912 Y-67.882;
G01 X-49.434 Y-68.454;
G01 X-47.962 Y-68.986;
G01 X-46.499 Y-69.478;
G01 X-45.045 Y-69.931;
G01 X-43.602 Y-70.348;
G01 X-42.171 Y-70.728;
G01 X-40.753 Y-71.074;
G01 X-39.349 Y-71.386;
G01 X-37.961 Y-71.666;
G01 X-36.589 Y-71.915;
G01 X-35.234 Y-72.134;
G01 X-33.897 Y-72.326;
G01 X-32.579 Y-72.490;
G01 X-31.280 Y-72.630;
76
G01 X-30.000 Y-72.746;
G01 X-28.740 Y-72.840;
G01 X-27.501 Y-72.913;
G01 X-26.283 Y-72.967;
G01 X-25.085 Y-73.004;
G01 X-23.909 Y-73.024;
G01 X-22.753 Y-73.030;
G01 X-21.618 Y-73.022;
G01 X-20.504 Y-73.003;
G01 X-19.411 Y-72.973;
G01 X-18.337 Y-72.934;
G01 X-17.284 Y-72.888;
G01 X-16.249 Y-72.835;
G01 X-15.233 Y-72.778;
G01 X-14.236 Y-72.716;
G01 X-13.256 Y-72.652;
G01 X-12.292 Y-72.587;
G01 X-11.344 Y-72.521;
G01 X-10.411 Y-72.456;
G01 X-9.492 Y-72.393;
G01 X-8.586 Y-72.332;
G01 X-7.693 Y-72.274;
G01 X-6.810 Y-72.220;
G01 X-5.937 Y-72.171;
G01 X-5.072 Y-72.127;
G01 X-4.215 Y-72.089;
G01 X-3.365 Y-72.058;
G01 X-2.519 Y-72.033;
G01 X-1.677 Y-72.015;
G01 X-0.838 Y-72.004;
G01 X0 Y-72.0;
G01 X0.838 Y-72.004;
G01 X1.677 Y-72.015;
G01 X2.519 Y-72.033;
G01 X3.365 Y-72.058;
G01 X4.215 Y-72.089;
G01 X5.072 Y-72.127;
G01 X5.937 Y-72.171;
G01 X6.810 Y-72.220;
G01 X7.693 Y-72.274;
G01 X8.586 Y-72.332;
G01 X9.492 Y-72.393;
G01 X10.411 Y-72.456;
G01 X11.344 Y-72.521;
G01 X12.292 Y-72.587;
G01 X13.256 Y-72.652;
G01 X14.236 Y-72.716;
G01 X15.233 Y-72.778;
G01 X16.249 Y-72.835;
G01 X17.284 Y-72.888;
77
G01 X18.337 Y-72.934;
G01 X19.411 Y-72.973;
G01 X20.504 Y-73.003;
G01 X21.618 Y-73.022;
G01 X22.753 Y-73.030;
G01 X23.909 Y-73.024;
G01 X25.085 Y-73.004;
G01 X26.283 Y-72.967;
G01 X27.501 Y-72.913;
G01 X28.740 Y-72.840;
G01 X30.000 Y-72.746;
G01 X31.280 Y-72.630;
G01 X32.579 Y-72.490;
G01 X33.897 Y-72.326;
G01 X35.234 Y-72.134;
G01 X36.589 Y-71.915;
G01 X37.961 Y-71.666;
G01 X39.349 Y-71.386;
G01 X40.753 Y-71.074;
G01 X42.171 Y-70.728;
G01 X43.602 Y-70.348;
G01 X45.045 Y-69.931;
G01 X46.499 Y-69.478;
G01 X47.962 Y-68.986;
G01 X49.434 Y-68.454;
G01 X50.912 Y-67.882;
G01 X52.395 Y-67.269;
G01 X53.882 Y-66.614;
G01 X55.371 Y-65.915;
G01 X56.860 Y-65.173;
G01 X58.348 Y-64.386;
G01 X59.832 Y-63.555;
G01 X61.312 Y-62.678;
G01 X62.785 Y-61.755;
G01 X64.249 Y-60.787;
G01 X65.703 Y-59.772;
G01 X67.144 Y-58.710;
G01 X68.571 Y-57.602;
G01 X69.982 Y-56.447;
G01 X71.374 Y-55.247;
G01 X72.746 Y-54.000;
G01 X74.096 Y-52.708;
G01 X75.422 Y-51.370;
G01 X76.722 Y-49.987;
G01 X77.994 Y-48.561;
G01 X79.236 Y-47.091;
G01 X80.446 Y-45.579;
G01 X81.623 Y-44.024;
G01 X82.764 Y-42.429;
G01 X83.869 Y-40.795;
78
G01 X84.934 Y-39.122;
G01 X85.959 Y-37.412;
G01 X86.942 Y-35.666;
G01 X87.881 Y-33.885;
G01 X88.776 Y-32.071;
G01 X89.623 Y-30.226;
G01 X90.423 Y-28.351;
G01 X91.173 Y-26.448;
G01 X91.873 Y-24.518;
G01 X92.521 Y-22.564;
G01 X93.116 Y-20.586;
G01 X93.658 Y-18.588;
G01 X94.145 Y-16.571;
G01 X94.577 Y-14.537;
G01 X94.953 Y-12.489;
G01 X95.271 Y-10.427;
G01 X95.533 Y-8.354;
G01 X95.737 Y-6.273;
G01 X95.883 Y-4.186;
G01 X95.971 Y-2.094;
G01 X96. Y0;
;
(ROTOR POCKET OUTLINE FINISHED);
;
(ROTOR POCKET STRAIGHT LINE COMMANDS);
;
G01 G40 X90.0 Y0;
G01 X82.0 Y0;
G01 X-82.0 Y0;
G01 X-82.0 Y9.0;
G01 X82.0 Y9.0;
G01 X82.0 Y-9.0;
G01 X-82.0 Y-9.0;
G01 X-82.0 Y18.0;
G01 X82.0 Y18.0;
G01 X82.0 Y-18.0;
G01 X-82.0 Y-18.0;
G01 X-82.0 Y27.0;
G01 X82.0 Y27.0;
G01 X82.0 Y-27.0;
G01 X-82.0 Y-27.0;
G01 X-82.0 Y ;27.0;
G01 X-73.0 Y36.0;
G01 X73.0 Y36.0;
G01 X82.0 Y27.0;
G01 X82.0 Y-27.0;
G01 X73.0 Y-36.0;
G01 X-73.0 Y-36.0;
G01 X-82.0 Y-27.0;
G01 X-82.0 Y27.0;
79
G01 X-73.0 Y36.0;
G01 X-73.0 Y45.0;
G01 X73.0 Y45.0;
G01 X73.0 Y-45.0;
G01 X-73.0 Y-45.0;
G01 X-73.0 Y45.0;
G01 X-55.0 Y54.0;
G01 X55.0 Y54.0;
G01 X73.0 Y45.0;
G01 X73.0 Y-45.0;
G01 X55.0 Y-54;
G01 X-55.0 Y-54.0;
G01 X-73.0 Y-45.0;
G01 X-73.0 Y45.0;
G01 X-38.0 Y63.0;
G01 X38.0 Y63.0;
G01 X73.0 Y45.0;
G01 X73.0 Y-45.0;
G01 X38.0 Y-63.0;
G01 X-38.0 Y-63.0;
G01 X-73.0 Y-45.0;
G01 X-73.0 Y0;
G01 X0 Y0;
;
M30 (CODE END);
%

80
 Appendix 2 Bearing data sheet

Deep groove ball bearings, single row, shield on both sides

Principal dimensions Basic load ratings Fatigue Speed ratings Mass Designation
dynamic static load Reference Limiting
limit speed speed
d D B C C0 Pu * - SKF Explorer bearing
mm kN kN r/min kg -

12 32 10 7,28 3,1 0,132 50000 26000 0,037 6201-2Z *

81
 BUDGET Steel Spur Gears
Materials
STD : Steel C45/080 M40/En8
BUDGET Steel Spur Gears 1.5, 2 MOD
Stainless
Appendix 3 Steel
Gear 303S21/304S31
Data sheet (En58) 20° P.A.
Materials
Spur Gears 1 mod cont. - Stainless (NOT Chemically Blackened)
STD : Steel C45/080 M40/En8
1,1.5
PART MOD
Stationary gear data
NUMBER
20°
MOD Teeth ØP ØD P.A. Stainless
ØM ØB A C Steel
E 303S21/304S31
1+ 5+ 10+ (En58)
25+

BUDGET
SG1-40
SG1-50
1
1
Steel Spur Gears 20 £27.65 £26.10
40 40 42 35 10 10 10 20 £22.77 £21.50
50 50 52 35 10 10 10 Materials
£20.35
£24.71
£19.32
£23.46
40 STD10 : Steel
10 C45/080
10 20 M40/En8
1,1.5
SG1-56
SG1-100
1
MOD
1
5620° 56
P.A.58
Stainless Steel
£35.79 £33.79
303S21/304S31
100 100 102 60 12 10 10 20 £76.51 (En58)£72.24
£31.98
£68.38
£30.37
£64.91
ØB
SG1-120 1 120 ØP
120 20 60 12 10ØM 10ØD 20 £83.02 £78.38 £74.19 £70.43

Spur Gears 1.5 mod - Steel

ØP ØB ØM ØD
(Chemically Blackened)
PART MOD Teeth ØP ØD ØM ØB A C E 1+ 5+ 10+ 25+
NUMBER
A C
ESG1.5-12 1.5 12 18 21 21 E 8 15 15 30 £6.52 £6.15 £5.83 £5.53
ESG SG

ESG1.5-15 1.5 15 22.5A E22.5 C

18 8 15 10 25 £7.17 £6.77 £6.41 £6.08
ESG SG

ESG1.5-16 1.5 16 24 27 20 8 15 10 25 £7.48 £7.06 £6.68 £6.34

ESG1.5-18 1.5 18 27 30 22 8 15 10 25 £8.43 £7.96 £7.54 £7.15
ESG1.5-20 1.5 20 30 33 24 8 15 10 25 £8.93 £8.42 £7.98 £7.57
Spur Gears 1 mod - Steel
Spur Gears
ESG1.5-22 1.5 1 mod 22 33- Steel 36 26(Chemically8 15Blackened)
(Chemically
10 25 £9.89 Blackened) £9.33 £8.84 £8.39
BUDGET Spur Gears

PART
BUDGET Spur Gears

ESG1.5-24
PART
NUMBER MOD
MOD
1.5 Teeth 24 36 39 28 8 15 10 25 £10.37 £9.80 £9.27 £8.80
ØP ØD ØM ØB A C E 1+ 5+ 10+ 25+
Teeth ØP ØD ØM ØB A C E 1+ 5+ 10+ 25+
ESG1.5-30
NUMBER
ESG1-12 11.5 12 30 12 1445 14 486 10 38 1510 25 15£5.6910 £5.38 £13.08
25 £5.08 £4.83£12.35 £11.69 £11.10
ESG1.5-32
ESG1-15
ESG1-12
11.5 15 32 15 1748 17 518 10 40
14 2010630 15
20 30 £5.8910 £5.57 £14.08
25 £5.26 £5.00£13.29 £12.58 £11.95
ESG1-16 1 1 16 12 16 181218 14 8 10 10£6.20 15£5.8525 £5.53£5.69 £5.26 £5.38 £5.08 £4.83
ESG1.5-36
ESG1-15
ESG1-18 11.5
1 18 15 15 17 17 8 10 20 30 £5.89 £5.57 £5.26£13.69
36
18 54
20 20 57 8 45
10 20 10 30 15£6.3310 £5.9725 £16.14
£5.66 £5.38£15.24 £14.42 £5.00
ESG1.5-40
ESG1-20
ESG1-16
11.5 20 40
1
20 2260 16 638 10
16 16 18 45
18
1012 20 15£6.5210 £6.15
8 10 20 25
30 £19.52
£5.83 £5.53£18.43 £17.44 £16.56
£6.20 £5.85 £5.53 £5.26
ESG1-22 1 22 22 24 18 8 10 10 20 £6.65 £6.28 £5.94 £5.64
ESG1.5-44
ESG1-18
ESG1-24
1.5
1 1 24 18
44 66
24 261820 20
69 8 10
45 12
20 10 820 10 15 10 25 £21.55
£6.98 20£6.5930 £6.24£6.33
£20.34
£5.92 £5.97
£19.26 £18.28
£5.66 £5.38
PART
ESG1.5-50
ESG1-25
ESG1-20 11.5
1 25 50 25 2775
20 20 20 78
228 1045
16 10128 20 15
10£7.1710
10 £6.7725
20 £24.31
£6.41 £6.08£22.95
£6.52 £6.15 £21.72
£5.83£20.62
£5.53
NUMBER
ESG1-26
ESG1.5-60
ESG1-22
11.5 26 26
60 28
90 22 93 8 10
50 10 12 20 15£7.4810 £7.0625 £6.68
£29.86 £6.34£28.19 £26.68 £25.34
ESG1-28 1 1 28 22 28 302222 24 8 10 18 10 820 10 £7.78 10£7.3520 £6.95£6.65 £6.60 £6.28 £5.94 £5.64
ESG1.5-80
ESG1-24
ESG1-30 11.5
1 30 24 24 26 20 8 10 10 20 £6.98 £6.59 £6.24£36.71
80
30 120
32 25 123
10 60
10 10 12 20 15£8.1010 £7.6425 £43.27
£7.23 £6.87£40.86 £38.67 £5.92
Spur Gears 2 mod - Steel
ESG1-32 1 32 32 34 26 10 10 10 20 £8.60 £8.12 £7.69 £7.30
ESG1-25
ESG1-36 1 25 25 27 20
36 36 38 28 10 10 10 20 (Chemically 8 10 10 20
£9.74 £9.20 £8.70 £7.17
£8.26 £6.77 £6.41 £6.08
1 Blackened)
ESG1-26
ESG1-40 1 1 40 26 40 422635 28 10 10 22 10 820 10 £10.54 10£9.9520 £9.43£7.48 £8.95 £7.06 £6.68 £6.34
PART
ESG1-44
ESG1-28 1
1 44 44 46 35 10 10 10 20 £11.31 £10.68 £10.10 £9.60
28 28 30 22 8 10 10 20 £7.78 £7.35 10+ £6.95 25+
£6.60
ESG1-50 1MOD50 Teeth50 52ØP35 ØD 10 ØM10 10ØB20 A £12.88 C£12.16E £11.511+£10.93 5+
NUMBER
ESG1-30
ESG1-60 1 1 30 30 32 25 10 10 10
60 60 62 35 10 10 10 20 £16.14 £15.24 £14.42 £13.69 20 £8.10 £7.64 £7.23 £6.87
ESG1-32
ESG1-80
ESG2-12 1 12 80 32 80 8232
12 24 40 3410 10
28 26
18 10 101020 20
10 10
£24.0010£22.663020£21.45£8.60
£8.43 £8.12 £7.54
£20.36 £7.96 £7.69 £7.15
£7.30
ESG1-36
ESG2-15 12 36
15 36 30 38 34 28 24 12 10 20 10 10 10 30 20 £9.89£9.74 £9.33£9.20 £8.84
£8.70 £8.39
£8.26
Spur
ESG1-40
ESG2-16 Gears12 1 mod
40 -
40 Stainless
42 35 10 10 10
16 32 36 26 12 20 10 30 £10.54 £9.95 £9.42 £8.95
(NOT Chemically 20 £10.54
Blackened) £9.95 £9.43 £8.95
ESG1-44
PART
ESG2-18 MOD12 Teeth 44
ØP ØD44
18 36ØM 4640
ØB A 35
30 C 12 10E 20101+ 10 10 5+ 30 20 10+£11.31
£11.94 £10.68 £10.67
25+ £11.27 £10.10£10.13
£9.60
NUMBER
ESG1-50
ESG2-20 1 50 50 52 35 10 20 10 10 30 £12.88 £12.08
20 £12.79 £12.16 £11.42
£11.51£10.85
£10.93
SG1-15 1 2 15 20 15 1740 17 448 10 32 20 12 30 £12.9310 £12.20 £11.55 £10.96
ESG1-60
ESG2-22
SG1-18 1
1 2 18 22 60 60 62
18 2044 20 488 10 35 10
36 20 1230 20 10 10
£13.7810 20 £16.14
£14.40
£13.0130 £12.31 £15.24 £14.42 £13.69
£11.69£13.59 £12.86 £12.21
ESG1-80
SG1-22
ESG2-24 1 1 22 80
2 24 24 22 248018 82 8 10 40 10 1020 10
48 52 38 12 20 10 30 £15.83 £14.1210£13.3420£12.62£24.00 £22.66 £14.15
£11.98£14.95 £21.45£13.43
£20.36
SG1-24 1 24 26 20 8 10 10 20 £16.14 £15.24 £14.42 £13.69
ESG2-30
SG1-25 1 2 25 30 25 2760 20 648 10 50 10 1220 20 £17.0310 £20.67
£16.0830 £15.21 £14.45£19.52 £18.47 £17.54

Spur Gears 1 mod - Stainless

32 64 68 50 12 20 10 30 £21.27
ESG2-32
SG1-30 1 2 30 30 32 25 8 10 10 20 £17.70 £16.72 £15.82 £15.02£20.09 £19.01 £18.05
ESG2-36 2 Unit 36 72 Ind.
14, Foxwood 76 Park,55Foxwood
12 Rd.20 10 (NOT
Chesterfield, Chemically
30 £24.83
Derbyshire S41 9RN£23.45Blackened)
£22.19 £21.06
21 .2
PART
ESG2-40 2Telephone+44(0)1246
40 80
MOD Teeth ØP ØD ØM ØB A 84 55 268080
15 Fax
20 +44(0)1246
10
C 30
E
260003£29.40 £27.83 £26.42
£31.14
1+ 5+ 10+ 25+
NUMBER
ESG2-44 2 44 88 92 55 15 20 10 30 £33.40 £31.53 £29.85 £28.34
ESG2-50
SG1-15 12 50 100
15 15 104 17 17 55 15 8 20 10 10 20 30 30 £40.88
£12.93£38.59£12.20 £36.53
£11.55£34.68
£10.96
ESG2-60
SG1-18 12 60 120
18 18 124 20 20 60 15 8 20 10 10 20 30 £58.60
30 £13.78 £13.01 £55.32
82 £52.36
£12.31£49.72
£11.69
ESG2-80
SG1-22 12 80 160
22 22 164 24 18 60 15 8 20 10 10 10 30 20 £84.45
£14.12£79.73£13.34 £75.46
£12.62£71.65
£11.98
SG1-24 1 24 24 26 20 8 10 10 20 £16.14 £15.24 £14.42 £13.69
Unit 14, Foxwood Ind. Park, Foxwood Rd. Chesterfield, Derbyshire S41 9RN
SG1-25
SG1-30
1
Telephone+44(0)1246268080
1
25 25 27 20 8 10 10 20 £17.03 £16.08 £15.21 £14.45
30 30 32 25 Fax 8 +44(0)1246260003
10 10 20 £17.70 £16.72 £15.82 £15.02 21.
Internal Gear data

83
 Appendix 4 Limits and Fits tolerences

Description Hole Basis Shaft Basis

More Clearance
(Close to Top of The Chart) Free Running H9/d9 D9/h9
Clearance Fits Loose Running H11/c11 C11/h11
Easy Running H8/f8 F8/h8
Sliding H7/g6 G7/h6
Close Clearance H8/f7 F8/h7
Locational Clearance H7/h6 H6/h7
Transition Location- slight interference H7/k6 K7/h7
More Interference Fits Location/Transition H7/n6 N7/h6
(Close to Bottom of The Chart) Location/Interference H7/p6 P7/h6
Interference
Medium Drive Fit H7/s6 S7/h6
Fits
Force Fit H7/u6 U7/h6

84
85
86
87
88
Appendix 5 tapping chart

89