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Design and Manufacturing of a Miniature Turbojet Engine

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Design and Manufacturing of a Miniature Turbojet Engine ( design-and-manufacturing-miniature-turbojet-engine )

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DESIGN OF MINIATURE TURBOJET ENGINE 48 difficult. Machining the channels between our fins required a 1/8” end mill. From speaking with WPI shop staff and consulting popular online machinist forums, we found that it is nearly impossible to avoid breaking 1/8” carbide end mills while machining Inconel for an extended period. We considered a variety of feeds and speeds, lubrication techniques, and tool paths in order to design a more efficient machining procedure for the turbine fins. However, we eventually determined that machining our turbine from Inconel 718 would incur too great of a financial cost and consume more than an acceptable amount of our time table. The failure of the Inconel turbine consumed an excessive amount of our time. Our initial attempts to machine the turbine from the Nickel super-alloy resulted in multiple broken end mills per blade and the machining operation was calculated to take upwards of twenty hours. In retrospect, we became too attached to the idea of using Inconel and committed to troubleshooting the problem instead of making an early decision to change the material. Eventually, we decided to machine the turbine from a disk of 316 stainless steel thus greatly reducing the machining time, tooling cost, and difficulty. The primary change in design, apart from the material, was a transition from a curved channel floor to a flat channel floor. The ramifications of this change are likely to be a slight decrease in efficiency due to the sharper edge of the blade channels. Additionally, 316 stainless steel does not maintain strength at elevated temperature as well as Inconel. Therefore, the change also decreased the turbines critical rotational speed. On the positive end, this decision decreased our machine

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