We are machining our miniature wooden roller coaster. In this video we take a look at the high-point station bent where the ride begins. Basswood, End mills, and Rivets will make this roller coaster happen.
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In this entry, we will be discussing our machining of the wooden roller coaster. We chose to machine our mini rides, and large ride supports, with the Taig CNC mill.
But let’s take a step back and discover where the numbers and code come from…
It all starts with our design phase. In the design phase we have a two dimensional (2D) plan look at where we want the ride to go. Once the layout is determined, we then move to the vertical layout.
This is where the calculations of kinetic and potential energy come into play. For this test track we have calculated one design hill. Based on theoretical friction values from our steel bearing wheels, we want the cars to apex the hill at one (1) foot per second. With these constraints in mind, we created a hi-order polynomial for the hill’s shape. Yes, remember back to Trig and Calculus.
Roller coaster hills are a combination of circular curves and varying parabolic curves.
If you use what’s called a “cross-product” you can cross the plan with the profile and make a three dimensional (3D) curve.
Now that we have our calculated support, or bent, heights, we can machine them with our CNC milling machine.
We begin by drilling the foundation holes and the holes to mount the track brackets. Our next procedure is to use an end mill and cut out the profile shape of the support to our design height.
Now the support is ready to be sanded to remove the holding tabs. Being that this was our first attempt at machining our supports, we kind of messed it up…
We accidentally broke the support while sanding with a router. Since we ruined the support, we decided to try using blind rivets that will hold the track brackets in place.
This design didn’t work since the rivet expanded and broke more of the support. Fortunately we have a few other tricks up our sleeves.
Follow along and “Like” our Facebook page and please offer any tips or suggestions to help build the Biggest Little ride. We’d love to hear from you, and want you to join the ride!
Our first attendance of the IAAPA Trade Expo was a complete success! So much so that we decided to patron the local parks of Orlando. By that we mean Fun Spot USA and the various Disney Parks.
Since we are close to the holidays, Disney was celebrating in grand fashion. Our first stop was the Magic Kingdom for Mickey’s Very Merry Christmas Party.
Disney spared no expense on Christmas decorations and hot chocolate. Throughout Main Street there were dozens of jazz bands playing Christmas tunes with a bit of Disney flare.
We took a spin the various, classic, rides throughout the park: Space Mountain, Big Thunder Mountain Railroad and the completely revamped Snow White and Seven Dwarfs mine ride. The swinging cars on the mine ride were extraordinary!
During the day the park was immaculately clean, but at night it turned into a Winter Wonderland…
We will be uploading a video to our Roller Coaster Log (the YouTube channel) soon with a video recap of the festivities. In the video you’ll be able to see the fake snow that blankets the park throughout Mickey’s Christmas Party.
Our next park we visited was the always changing EPCOT.
Although EPCOT is promoted as a more educational theme park, it has been updated and reimagined throughout the years. One of their greatest rides is Mission Space.
Mission Space simulates Man’s colonization of Mars by subjecting its riders through “astronaut” training in a large centrifuge. The Imagineers are simply brilliant, and their execution of space exploration is unparalleled.
The next stop in EPCOT was another signature “hi-tech” ride: Test Track. Test Track takes your simulated car through rigorous hi-speed maneuvers and tests. The highest speed is reached at the end at 64.9 mph.
But, the largest jewel in the EPCOT crown is the EPCOT World Showcase. There are eleven countries on display around the lagoon and each portrays the culture and customs of the country represented.
EPCOT’s signature night time finale is a grand firework show, and the Christmas decorations were a perfect accent to the park’s beauty.
Our last Disney stop was to Disney Hollywood Studios. This was a first for us, and it proved to be our favorite. No offense to the Magic Kingdom.
One thing to note about Disney Hollywood Studios portrays a Hollywood and vaudeville of the 1930s. Since it looks much the same Los Angeles and Hollywood currently do, it’s actually done to a better degree than the real thing.
One of the best rides in the park is the Rock n’ Roller Coaster with theme music by Aerosmith. The ride is a Vekoma LSM launch roller coaster shrouded in darkness and New York City traffic.
Look for Updates from the IAAPA International Amusement Park Trade Expo this week, we will be doing a multipart post along with videos.
Getting down to brass tax…
After finishing the fixture plates from a previous post, we decided to test it out by machining our highly anticipated Aluminum Car.
The fixture worked as anticipated, and allowed for precise repeatability.
In these pictures, below, you can see where the wheel assembly was carefully milled out with a combination of quarter inch and three sixteenth inch end mills.
Once the car pattern was machined from the stock, we then spotted and drilled the alignment pins that will lock the wheels into place. Afterward, the excess aluminum was milled off to match our design measurements.
Now the final seat components had to be machined from aluminum and ABS plastic for the seat backs.
All that remains is to have the windshield engraved and the chassis painted with red and black.
We have finished the fixture plate! Our first attempt at repeatable machining was a success. Checkout the video below and subscribe to our Roller Coaster Log!
Using our quarter inch carbide end mill, we milled out some 6061 aluminum. After the plate was machined per the design, we moved to the drill press to drill and tap holes to hold fixture clamps.
The holes were first spotted with the milling machine, then drilled with a 3/32nd inch HSS bit. After creating a pilot hole, so the drill bit doesn’t walk, we used a number 21 bit to fit the hole for the tap. Lastly, we used a 10-32 HSS bottoming tap bit and used the drill press to align the hole.
Using a drill press for tapping works wonders, but there is some manual “elbow grease” that will have to be applied…and a lot of cutting fluid. WD-40 works well for machining aluminum.
Below is the finished plate with Mitee-Bite®: fixture clamps. These clamps will provide roughly 250 pounds of clamping pressure. With cut and surfaced stock, the fixture holds properly and allows for repeatable milling and accuracy.
This update is showing off a few things happening around the shop: progress, cleanup, and happenings.
Something we’ve been working on and will put into use once our fixtures are complete are “finishing” cuts on milling operations.
Now you might be wondering why we haven’t been performing this operation before now. Well, we haven’t really needed a nice surface finish until now. Since we will be anodizing finished roller coaster cars, having a smoother surface finish gives the anodized layer much more appeal.
Moving on, you may remember that we had to update our Taig Micro Lathe to a larger turning machine a few months back. We finally listed and sold the li’l Taig recently on eBay®. We had to perform our “own” packaging antics. Basically a trial run for shipping mini coasters.
And now the cleanup effort…
We had a slight mishap last time we attempted the anodize process. Our dye tank needed to be heated to help the aluminum absorb the coloring; however, the jar we were using cracked under the heat and exploded. The resulting mess was that of a large oil spill on the shop floor…
We attempted to pour a degreaser and water solution onto the concrete floor to soak for a bit, then we covered the area with kitty litter. It didn’t work too well. We will be looking for other, non caustic, ways to remove the stain. Any and all suggestions will be beneficial, so we look forward to hearing them through our Contact Page.
Since the key to making repeatable parts is a fixture plate, we decided to try our hand at cold rolled steel milling.
We purchased a new “hogging” end mill from McMaster-Carr along with our steel and aluminum plates. There will be a video uploaded soon about the fixture making process and our massive friction saw. Sparks fly EVERYWHERE.
The next step, after sawing, was to square the large plates. Since we’ve performed minimal steel work, this posed a bit of a challenge. But, we have learned to alter the speeds and feeds at which the spindle crosses the part. The outcome was fairly successful.
The next few weeks, we will be preparing for the IAAPA International Attractions Trade Show in Orlando, Florida. We will be meeting with the “big boys” in the industry and making valuable connections. So look forward to our updates beforehand and during the thrilling experience!