During my first semester at Rensselaer, I used a variety of different turning and milling processes in order to create a machined train. In order to receive a passing grade, the train needed to be machined within the stated +/-0.002 inch tolerance in order to receive a passing grade.
The CAB:
The Cab was machined from a solid block of aluminum.
First, we were required to mark and drill a shape in the center of the train which is where the cab would eventually be situated.
Next, we counterbored onto the other side where the screw would eventually be placed in order to fix the boiler mechanically to the end of the cab.
Once the drilling was taken care of the side shape of the cab would be roughed using a vertical band saw.
Once the aluminum had been band sawed successfully, it would then be machined using a vertical mill bringing the finish to the +/-0.002’’ tolerance.
The Boiler/ Chimney:
The boiler was by far the most time consuming part of the machining process as it required a variety of different lathe operations in order to be completed.
Before it was put on a lathe it needed to be drilled and counterbored as shown on the diagram.
Once this was accomplished a cutting tool was used in order to make the ridges as well as machine down the boiler and chimney.
The end of the chuck needed to be drilled into before being removed using the parting tool. The un-angle cut section between F and H would be used as the base to remove it from.
