特斯拉无叶涡轮泵制作方法.docx
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特斯拉无叶涡轮泵制作方法.docx
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特斯拉无叶涡轮泵制作方法
特斯拉无叶涡轮泵制作方法
BuildingaTeslaTurbinefromharddriveplatters
PleasenotethatIamnotaPhysicistoramachinist(yet).IhavebeeninterestedinNikolaTeslaforsometime,andIwaslookingforaprojecttogainsomeexperienceinthemachineshop.MyjobistoprovideLectureDemonstrations,somygoalwastoproduceateachingtoolratherthananefficientengine.
Forbackgroundmaterial,WikipediahasseveralgoodreviewarticlesaboutNikolaTesla,theTeslaTurbine,theBoundaryLayerEffect,andReynoldsNumber.
Disks
AtfirstItriedusingCDsbecauseoftheirlargesurfaceareas,buttheydidn'tholduptoowellunderthemillingmachine.Ialsohadastackofplattersfromoldanddefectiveharddrives,butIdidn'tknowifthesmallerdiameterdiskswouldworkaswell.
OneproblemIranintoisthatsomenewerharddrivesuseceramicdisksinsteadofmetal.They'restillcoatedwithmetal,butthey'rethinnerandacoupleplattersshatteredwhenItriedtomachinethem:
Myoriginalplanforthecenterholepatternhadsmallholes(forthreadedrodsandwashersforspacers),aswellaslargeholes(forairvents).
ThesecondsetofplattershadradialarcscutinthemsuchthattheinsideedgeoftheradialcutoutisclosetotheoutsidediameterofthespacersthatIremovedfromtheharddriveassemblies.
Theharddriveplatterswerestackedandclampedtoarotarytablebetweentwosheetsofscrapaluminiumbutthetopdisk(abovepicture)stilltooksomeextradamage.Therestoftheplatterslookmuchbetterthough(seethecompleterotorassemblybelow).
Spacers
Idecidedtobelazyandusethespacersthatwerebetweentheplattersintheoriginalharddriveassembliesratherthanmachinemyown.Thisincreaseddistance(roughly.05"insteadof.012")mayleadtoturblentflowratherthanlaminarflowbutwillbecloseenoughforthisproject.
Shaft
Withtheturbineplattersandspacerscomplete,Iturnedashaftfromroundstock.Theinsidediameterofboththeplattersandspacersis.98"whichisthediameterofthethicksectioninthemiddle.Ileftthewholelengthat.98"untilIknewthewidthofthechamberandtheinsidediameterofthebearings.Thewidepartis1.77"longwhichfitsinsidethe2"thickacrylicchamber.
Collars
Thecollarsareessentiallywiderversionsoftheplatterspacers.Theinsidediameterhastofitontheshaft,buttheycan'tbetootallsotheyblocktheventilationholesinthedisks.Also,theycan'tbetoowideortheywilltakeuptoomuchhorizontalspaceinsidethechamber.Imadeeachcollar.3"whichisenoughspacefora#10-32setscrewtoholdthem(andeverythingelse)inplace.
Bearings
Thebearingsandbrassfittingsweretheonlynewpartsinthisproject(everythingelsewasreusedfromscrapmaterials).ThesemetricbearingswerepulledfromaboxofoldandusedbearingsandIhadtomachinetheshaftandsidepanelstofitthem.
RotorAssembly
Thereareelevenplattersandtenspacersheldtogetherbythetwocollars.TheharddriveplattersarehardtokeepcleansoIworegloveswhenassemblingtherotor.Thereshouldbeafairamountofpressurebetweenthetwocollarsorthediskswillrotateabouttheshaftinsteadofwithit.
Chamber
Themainchamberisanacrylicblockmachineddownto4.75"x4.75"x2".Thesquareblockwasmountedina4-jawlathechuck,drilled,andthenboredout.Thefinalcutoutisabout.07"largerthanthedisks.Theairinletistapedfora1/4"pipethreadandalloftheotherholesaretapedfor1/4-20socketheadcapscrews.
SidePanels
Thesidepanelsare.47"thickacrylicandhaveuntaped.25"holesforalignmenttothemainchamber.Thecenterholeis.6"witha.280"deepcounterboreforthebearing.ThebearingsaremetricsoIusedthe4-jawchuckandboringbaragaintotryforapressfitintothesidepanel.However,Imadethecounterboreafewthousandthstoobigwhichallowsthebearingtorotateinthesidepanel.
ManyotherTeslaTurbinesthatI'veseenonlinehavelargerventilationholesinthesides.Iwasgoingtocutthesameradialpatternfromthedisksinthesidepanels,butIdecidedthatwasn'tnecessaryafteratrialrunwithjustthe.6"hole.
Assembly
Thetwobrassfixturesarea5/16-45tubeunion(picture5),anda1/4tube,1/4pipehosebarb(picture6).
CompleteTurbine
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