eva aS a at MODEL ot EERMODEL SUBSCRIPTIONS UK. New, Renewals & Enguiies Tel 0344 243 9023, malt help@me securerdes.co.uk USA & CANADA New, Fenewals & Enquiries Tet: (001)-866-647-9191 REST OF WORLD - Now, Rene Tel +44 1604 828 748 mall help@ene secured: co.uk CURRENT AND BACK ISSUES lub News Eliter Get Theasby PRODUCTION Designer: Ye Green Imustrtor: Grahame Chambers Retouching Manager. ian Vickers ‘Ad Production: Any Tompuins ADVERTISING Advertising Sales Executive: Angela Pine Email angela price@mylimemedia com (MARKETING & SUBSCRIPTIONS ‘Subscription Manager Bath Ashby MANAGEMENT (Group Advertsing Manager: Phone Bolger mal hana bolgerGerytrnernasa.com Chiet Executive: Ovien Da mytimemedia ti a Suse Qrrecycle www.model-engineer.co.uk waetancommedeagiesnotshp IN THIS ISSUE Vol 227 No.4676 22 October - 4 November 2021. 548 SMOKE RINGS News, views and comment on ‘the wad of model engineering 549 ECHILLS WOOD John Arewemith attends the standard ‘gauge rally tthe Echils Wood Railay. 554 AN ASTRONOMICAL BRACKET CLOCK ‘ion Garner makes abracket clock inspired by Tompion and Banger’ equator of 1708 557 ENGINEERING'S LOCAL HEROES - JAMES NASMYTH Roger Backhouse looks at thei of ‘amltalented artist nd engines, 562 BOLTON CORPORATION NO. 140 IN 1:16 SCALE Ashley Best bls 2 mol ofthe first of Bolton Comoran first fully enclosed ams 565 BOOK REVIEW Roger Bacthouse reviews Thompson ~ His Lifeand Locomotives by Tim Hille Graves. 566 DARLINGTON'S NARROW GAUGE DREAM FACTORY Mark Sithers explains Daringlons move into the production of narow-gauge locomatives 569 POSTBAG Reader eter. foe i Hod aly.» | 570 RECYCLING A 3% INCH GAUGE LNER PRAIRIE Robert Hobbs rescues an LNER V4 locomotive fom te scrap heap. 572 CAD AND 3D PRINTING IN MODEL ENGINEERING luis Tincaocscovers hat earing how tous 30 CAD wall worth the effort 576 HOW TO FIRE AND DRIVE YOUR PANNIER TANK Doug Hewson explains what todo with ‘your GMA panier tank, having completed constuction. 580 IN DEFENCE OF THE ORIENTAL MILLING MACHINE Nick Fast finds that workshop machinery from the Far East can represent goo valu for money. 584 FLYING SCOTSMAN | N5 INCH GAUGE ter Seymour Howell buds gh detiled Scotsman based on Dan You drawings. 587 INJECTOR WARS! arc Alien sees mode engineering {urn ino a competitive spor. 590 CLUB NEWS Geoff Theashy compiles the latest from model enginng cubs around the wor 543)CAD and 3D Printing ~ in Model @ PARTI Engineering cap nn, 7: Following an interest in model us aes cmtennaster ind reuaeelausen opens up a whole new 3D printing are used but | set of possibilities. have not seen much written ‘on Backyard Foundry Technics —_ (CAD) with two intentions; first, and 4663 (April 2021). drawing, avoiding traditional After completing a James: (old) methods. 1), a two-year project (I'm slow), _ | realized that | could generate Pa a rte ence [z) ora mea ance Selecting CAD software {sa starting point, did an Internet search for Best free CCAD software’. found alot of software such as Fusion 360, autocad and Onshape, ‘among many others. | also ‘spoke with friends and ended up choosing Onshape, which has @ free and a subscribed option. From now on, this software is only referred to as, CCAD, since for other platforms there are certainly similar concepts ‘Onshape is cloud based and does not require instalation ‘on the computer. This means we do nat need to update software or take up disk space. New updates are immediately available. The files containing ‘our drawings are saved ‘somewhere in a cloud. We donot have to worry about backup copies, Just sign up and start using In the free version, our drawings arein the public domain. They can be accessed but not edited by other users. However, they can be copied and changed, This 872 Model Engineer 22 October 2021version cannot be used for Part Studio commercial purposes, unlike As the name implies, this is the professional one, where where we design one or more projects are private. Itis a pans. requirement to be connected There are several sketching tothe internet, preferably ata tools available, such as, reasonable speed, Line, Rectangle, Circle, Text, tt can be installed on a Dimension, Extrude and many smartphone or tablet but | find more. The bedplate Part Studio iteasierto use on alaptop or is shown in fig 1 desktop. There may be a merged Part - ‘Studio with two components, Learning CAD for example the tiywhel Touse any CAD software, _with the eccentic attached. it's helpful to have some ‘These two parts can be drawn knowledge of three-dimensional separately and then combined. geometry. At the beginner's: ‘There may also be a Part Studio level,wecan star without with several parts for example, being experts inthe field the diferent ypes of nut and A‘Learning Centre” bolt that will be used (fig 2). is availabe with lots of Basicaly in Part Studio, we information on vdeo and make our sketches (drawing text, where descriptions of | intwo dimensions). After the avaiable features are easy _sketchis done, an Extrude tool tofind. YouTube is another__is used to add volume to our Source with hundreds of video part. For example, to make a1 tutorials onthe topic inch cube, we sketch a1 inch Aproject has three ‘square and then extrude one components or design tools: inch from one of the faces. Other tools could be used ike + Part Studio: Revolute instead of Extrude, “Assemblies to obtain other parts. More + Drawings information about this later. We can assign the type ‘of material to the part and ‘obtain, for example, the total volume, weight, and centre of mass. Imagine drawing ‘locomotive wheel with @ ccrankpin and balancing it by placing a counterweight ‘on the apposite end until you get the centre of mass at the origin of the axes. | have never tried this and CAD AND 3D sheet metal part and obtain a flat pattern of it It can then |__be exported to a drawing, ‘This has a possible use, for ‘example, in boiler cladding, Assemblies This is where the various parts created in Part Studios are joined to obtain the final product (fig 4). All parts needed from the various there are certainly better and Part Studios are added and tested methods, but the idea__ placed where required using remains. the so-called Mate Features to ‘Another interesting feature define the relative position or is the possibilty of using variables. When creating @ Part Studio for tap boxes, a sketch was made where the diameter and length of the ‘movement, As an example, the ‘outer surface of the crankshaft shaft must have a ‘Cylindrical Mate’ with the hole surface of the main bearings. tap canbe inserted. Then, the There are several Mate entire drawing is automatically Features such as: updated. This way we avoid having a part drawn for each dimension of tap box. ‘Spur gears can be created directly as shown in ig 3. The parameters are defined by the user and the drawing is ‘automatically generated. ‘Another interesting + Fastened mate + Revolute mate + Slider mate 1 * Planar mate + Oylindrical mate +Pin slot mate + Ball mate + Parallel mate + Tangent mate Bedplate design. A selection of fixings. ° \s es -\20e BeRe- COasmma-weoe- fe home toon ED Sic eer a) : =e a Creating a spur gear. The complete design for SH1-LT. ‘www.model-engineer.co.uk 573RS) SX Ses Cross sections can be created. translucent view. iol Interference detection. In Assemblies, we can make sections according to plans defined by us (fig 5). ‘The Translucent’ mode allows you to have an X-Ray type view (fig 6) ‘An Exploded View’ can show the placement of some ‘components (fig 7). ‘Another interesting feature in Assemblies is ‘interference detection’, which allows us to identify whether two or more parts interfere; see the example inred in fig 8 where one of the bands was 874 deliberately moved out of place. The red part is the result of the interference detection between band and cylinder, ‘Another interesting possibility in Assemblies is to make an animation. Drawings Drawings are generated using existing templates or by creating our own, The parts tobe placed on each drawing sheet are chosen. Cuts can be included, isometric views and Navigating the CAD tool. Itis not my intention to present tutorials, rather to provide clues. Although | have a background in electronic engineering, these topics were new to me. the necessary dimensions (fg an Excel spreadsheet, with 9). Generated drawings can be the advantage of having an ‘exported in various formats identifying icon (fig 10). suchas pdf or jpg.savedon Although | mentioned at your computer and eventually the beginning that | had no Printed on paper. intention to write a tutorial, Tutorials found on this topic I cannot resist presenting are usually quite explicit ‘a small example of the The various design tools construction of a 25mm cube (Part Studio, Assemblies and with a 10mm hole in the centre Drawings) are visible on the of one of the faces. The top screen of ourprojects. The edges of the cube are then. view is identical to sheets on rounded. Note that you can Model Engineer 22 October 2021CAD AND 3D | kare Your Free subscription ony allows public data. Try Onshape Professional to rea Searchin My Orshope @Myonshape > Casteamengine ‘Sketching the basic shape. @ MyOnshape © Recent opened Dcresteabyme [B shared wih me easly © Public nO ial Creating a new part. Defining how the part ime is to be extruded. fas > Ze Geeee-0OasmGa- are oO Se lo “eso (aie The fillet is added. configure CAD software to circumference. Extrude tise imperial measurements 25mm (fig 13). instead of metric. + The result isthe cube with a The folowing description is hole (fig 14). simplified and does not replace ~All is placed with a radius more elaborated tutorials. ‘of 2mm atthe desired edges 6g 15). + Create anew document _ (fig 19). Engine built Create a sketch ina Part Studio sheet. Draw the square and hole circumference (fig 12). + Select the zone inside the square and outside the After designing all the parts needed and making the required drawings, it was Myford time, and the result is in photo 3. ‘www.model-engineer.co.uk ‘complete SHIT, Avvideo was posted on YouTube showing the various Part Studios for this project, an ‘Assembly with animation and ‘a drawing, Search for'SHI LT \V2- Small Horizontal Steam Engine Design using Onshape! ‘and you should find the video. Please excuse the video quality. tis my next priority to eam more on how to create ‘and edit videos. (Tobe continued. 575CAD and 3D Printing in Model Engineering ..... ly Selecting a30 printer Once Id started to use CAD, it ‘was time to buy a 3D printer finds that Which one to choose? Again, piv | turned to the usual sources - people already using 3D opens up a whole new printers and the internet. There set of possibilities. are many options. l ended Up selecting a Chinese made printer from Creality model Continued from p.575 Ender3 V2 (photo 4). Although MLE 4676, 22 October 202 | purchased the printer from a Spanish website and Ilive in Portugal, delivery to my door took 26 hours, which, in Covidi lockdown times, is excellent. | paid around €280, shipping included, The filament (@Dink), which is the most Usual type is about €20 per 1kg reel and was bought locally There are many videos about this and other printers on the Internet, which comforted me, because | found answers to almost any doubt | had. ‘The printer works in millimetres, so CAD was configured accordingly Luis Trincao Assembly and initial experiments This printer comes partially assembled and with intructions for completing assembly and set-up. Nothing that should scare a model engineer - but my advice is to look for videos on the subject. They can help more than the attached instructions, There ate also many hardware and software upgrades possible Upgrading software is a must ifthe latest software version does not come with the printer ‘Awaming: some dexterity is required to perform some of the operations. Luckily there is alot of information available. Ive done it with no problem, To find the best place to instal the printer, one must considera few factors such as: 638 ‘realty inkjet printer, model Ender Noise ~ A30 printer is usually noisy and 30 printing is slow. Moisture - Affects the filament. Amoist filament will have printing issues. Dust - Makes printing difficult and is harmful to the printer mechanics and electronics. Light and temperature - The printer can operate without light; direct sunlight exposure and high temperatures can be harmful Power supply ~ Interrupting @ 3D print due to a power failure may force you to start printing the part from the beginning, This is very annoying if we are ‘almost at the end of several hours of 30 printing, Some printers can save their work and resume where they left off Before the first use, and from time to time, you will need to level the printing bed and adjust the stepper motor belts. ‘These are simple operations. ‘Some printers come with a bed auto-evelling device. Main parts on atypical printer Power supply ~ Provides DC power to electronics and stepper motors. ‘Mainboard ~ The brain of the printer. Display and controller This is. where we receive information from other parts of the printer ‘and send commands. ‘Bed - This is where the partis printed. Can be heated in most printers, Model Engineer 5 November 2021Mini di holder. Bed leveling screws ~ One in each comer of the bed. ‘Stepper motors = Control extruder and axis movement Extruder ~ Pushes the filament tothe hot-end. Bowden tube ~ Creates a path for the flament from extruder to the hot-end. Hot-end ~ Receives and heats the filament. Ends in the nozzle Fans - Used to cool the mainboard, hotend and printed part. This is where most of 3 printer noise comes from. Xaxis - Movement left/\ight. Uses a stepper motor coupled by belt. Y axis - Movement front/back. Uses a stepper motor coupled by bet. Zaxis ~ Movement up/down, Uses a stepper motor coupled by leadscrew. For more detailed description, please consult specific printer information, Required software Between each layer, the hot end (where the filament is metted and placed over the previous layer through the nozzle) moves away from the printing bed, typically by 0.2mm. To start printing, we reed an'STL' (from ‘'STereoLithography) format file of our part. This is exported from the part drawn in the CAD program. In my case, using Onshape, this file is generated from a Part Studi Then we need to send that file to another program called the'slicer. After research and advice, | selected Ultimaker Cura, hereinafter referred to as Slicer. It's free to install, and widely mentioned on the Internet. There are many other slicer programs you can choose from. The Slicer needs to be set to the printer being used. For each part to be printed, several parameters will be configured. 30 printer operation is based fon successive layer deposition of melted plastic (filament) with a pre-set thickness to obtain the desired volume. Here are some of them: ‘Build plate and printing temperature ~ It depends on the type of filament used and other factors. ge nde box. Layer height - Influences the final quality of the part. ‘Typically, between 0.12 and 0.28mm, ‘Infill density ~ Usually ranges from 10% to 100%. In most ‘cases, the parts are hollow to save filament and printing time. Print speed - Usually around ‘50mm/sec. Higher speeds can affect the final quality There are numerous other configurations that can be set by users, Slicing the ‘STL file, we get a'g-oode' type file, which is what we need for the printer to understand. We also get an estimate in meters and grams Of filament to be used and the approximate printing time. Do not be surprised by long printing times as 30 printing isa slow process, at least on non-professional printers. Before sending the g-code file to the printer (on a micro ‘SD card in my case), one can simulate in the Slicer how the print nozzle will work layer by layer. For those more curious, you ‘can edit the g-code fie in any ‘Table 4. Filament types Filament | Properties/Uses Durability | Strength | Typical Temperature (°C) Nozzle Bed PLA Easy to use and Medium [Medium | 200 60 biodegradable PETG Flexible and durable High Medium — | 230 70 Nylon Strong, flexible and High High’ 240 35 durable ABS Durable and impact High Medium | 230 20 resistant TPE Very flexible rubber-ike | Medium | Low 230. 45 Wax Lost wax castings | Low Low 150) 20 www.model-engineer.co.uk CAD AND 3D text editor. Then you need a list of g-code commands and their meanings to understand what ‘the printer will do with them, Interesting .. But good luck ‘and be patient Filament There are several types of filament available. The co called PLA polylacticaci) is fone of the most used. There ‘are many colours, even fake wood or metal, The usual siameters of laments ace 1.75mm and 2.85mm. In the filament table (table 1),a comparisons made between some different ‘types. For each type, the slicer/rinter must be configured accordingly. Bed and nozzle temperature are two of the most important settings. Please note thatthe temperatures shown on the table are for reference only. “The ideal printing temperature fora certain type of filament ‘can vary from brand to brand. “There may be limitations on certain types of printers for ‘some fiaments. 30 printings Here ae some parts printed in 3D indicating their origin and any specific Features. For ‘Some parts, a way to access the generated CAD files is provided for you tose at will ‘Support for mini dill (photo 5) Particularly useful for cutting small stock at right angles. STL files ave available at www. thingiverse.com. This site is free to use. Try searching for ‘Dremel’ or'Myford! and you'll find several interesting prints. The files provided are‘STE => 639Nene Yate Ye at at + Tam a Variable table > % Le] = I To view variable table format, so they will have to be submitted to Slicer to generate Parameterised design the gcode file for the printer. Thethvee paris showntook | (LEP EL for atieee:tap box: more than 16 hours to print. Edge finders box (photo 6) box STAP Here, one must will not close. Do not ask how filaments helps to identify My design. The project is insert the variable values (in _1 know. the type of tap. available on the Onshape millimetres) as follows to set *To set thetext on the side of _ When 3D printing with PLA, website with the name the size of the box (figt 6): the box fig 17), select edit the parts tend to shrink atte, "TAPBOX_LT' (TAPBOX_LTF- on the TEXT feature, placing so inmy drawings | include a >Edge Finder). if you have *DIAM- Larger diameter of the desired text and changing shrink factor of about 3% access, feel free to search for _the tap. its dimensions if necessary. this filename, make a copy —_* ALT - Tap length. This text will appear in low _‘Mlyford tumbler gears (photo 8) and use as you wish *Folga-Youcan leave as it relief andit canbe painted From wwww.thingiverse.com. 1 Three tap box (photo 7) is (0.2mm). It sets the gap with @ marker- but be careful, have never tried them on the Also my design and available between the base and the if the paint is too thin it will lathe and | hope I never have to. inthe file TAPBOX_LT>Tap_ cover. Without a gap, the box blur. Using different colour __In the photograph, my spare set is in Tufnol and those printed by the 30 printer are in yellow. EA 2s BEPRBO OO a4TR BVO ‘entication labels bial aap = © Setting the text on the tap box. | (Photos 9nd 10) v7 ‘An upgrade to the former genruoe rn handwritten paper labels. The o r first layer of Imm is printed in ; white with black letters in high Estrus a relief of 0.6mm, @ bevieant Here we print two colours Fenda of filament in sequence in the Geindes ‘same part. Bendes Bennde7 Bendes Shon dmerlons OFiers Ad etecbon ttle. Conamter ie Hie ctnesetehes ‘Myford tumbler gears, 640 Model Engineer 5 November 2021Do not be surprised by inting times as 55, at least ng isa sl 1 non-professional printers. Proceed as follows. white base. Then change to black filament and order the printer to continue printing. To change the filament, the extruder must be sufficiently hot, otherwise the filament is trapped. After changing it, you should push out any remaining white lament until black filament appears. | will not give details on the insertion of the g-code command to pause the printer because it depends on the slicer used. find it easier done than said. Usually itis a * Design your label in CAD. * Generate an'STU file and send it to the Slicer, * In the Slicer, insert a g-code command that will order the printer to pause when it finishes printing the white base. * Generate the g-code file for the printer and start printing with white filament. The printer will stop as soon as the pause g-code command is reached after printing the Moreidentifeation abel www.model-engineer.co.uk CAD AND 3D 30 printed Dickson toolholder mount. menu driven operation, sono programming skills are needed. I struggled initially because my printer did not have the latest software version and did not pause as wanted. Once the software was upgraded it «il stained it immediately. The Next ones were printed in black. Conclusion This article is only an introduction to CAD and 30 printing (and a large part of my worked right away. knowledge). | hope it is helpful. The seeds are sown, As for me, Dickson style toolholder mount will continue to learn. (fig 18 and photo 11) My design. Also availblein Acknowledgment thefile TAPBOX_LT>QC.Itis_ Tomy dear friend Alexandre different from what is generally available because itis inclined at 45 degrees. | found it easier to.use. In the drawing provided, the angle of inclination can be changed, The first one was Rodrigues, specialist in ‘Computer Aided Design, ‘amongst other things, for his help with suggestions and correcting the English version of my article. printed using white filament but ME lea lo = Dickson tooholder mounts 641