Hands-on/gloves-on experience is crucial in the class. The students utilize numerous methods and machines during the semester-long project.

Creating the mold

To cast the flywheel and frame of the engine, the students pack down sand mixed with oil and other binders into a metal pattern. They use a tamper and a large hammer to pound down the sand to a dense shape.

Pour the metal

Bars of metal, known as ingots, are melted down in the lab's induction and resistance furnaces. The student wears goggles, a heavy shirt and gloves to use the long tongs to extract the glowing crucible of shiny molten metal, which is then carefully poured into a mold. The liquid metal goes into a small hole of the mold. When it comes out of the second hole, it means the mold is full. Flames and smoke shoot up during the process.

Break out the parts

After waiting at least 15 minutes to cool, the molds are broken to reveal the shiny, fresh engine parts. Vincent Shiue, a mechanical engineering senior, said there are some reject parts on occasion, but the success rate is high.

"If the metal isn't hot enough or if we don't pour it fast enough, it'll solidify too early and get stuck," Shiue explained.

Parts must be perfect

The students then sand down excess metal before utilizing mills, drill presses and lathes to make sure the parts will fit securely. LED screens show measurements down to a 10,000th of an inch. The measurements show where the parts must be machined down further and where holes will be drilled.

"This is full-scale manufacturing gear," said Ed Herger, a lecturer in mechanical engineering technology. "Most students enter here not knowing these machines but leave here knowing how to make engines. They put in quite a lot of work."

Air flow

Each engine is tested with an air flow rate of 40 cubic feet per minute at 40 pounds per square inch. The four holes drilled through the frame by the students guide the air through the engine -- two holes going horizontally are attached to the air source to push the piston. The other two are for exhaust.

Successful engines make the grade

Students are allowed to make modifications to their engines to improve performance and grades. Top engines usually get to about 4,000 rpm. More powerful rates like that are usually due to students going beyond the original specifications by reducing weight and improving balance on the flywheel.

"It's as much work as they want to put into it," Herger said. "I expect they'll get better and better."

Students like Shiue are already benefiting from the project's beginning-to-end process.

"It's important to know what the construction process is so you know how to design or know what manufacturing processes are necessary to make certain pieces," Shiue said. "You have to understand all of the steps you have to go through to make the final piece."

Original story here.