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Burl, Jonesy,
Great find on the car outline. I would never have thought that the entire car would have been canted to the center. Pitching the bottom tangent to effect drainage makes sense. I don't follow the logic of the top tangent though unless the car is a cylinder with a miter cut joint at the center. Oh well, live and learn. Thanks guys.
Bob C.
 
:D Thanks guys, I didn't realise that a innocent query was going to be such a discussion point. I am glad to see it has helped. Paying it forwards the help I have received since being on here.
 
Discussion starter · #26 ·
Anybody have any thoughts about how the cut in the middle of the tank shell, where the V is formed, is made? I assume it would be cut flat, and then rolled into a cylinder. I wonder if there's a formula for it that some of the machinists out there would know.

I can use Sketchup to intersect a cylinder at a slope with a square, but I don't know any way to "unroll" the cylinder to know what it should look like flat. I guess if I can't come up with something better, I'll print a ring with one face sloped, and wrap card stock around it to trace the line.
 
Burl - The higher end solid modeling packages will 'unroll' a cylinder of any shape. The issue is laying out the flat pattern. IF we assume that the tank is two mirrored parts of cylindrical shell, mitered to fit at the center it is a no brainer for my cad software at work. My suggestion would be to provide me the OUTSIDE DIAMETER you are going to use either in prototype feet/inches and the scale you are going to use, or the actual diameter in inches. That along with the proposed slope/angel and the rest is easy peasy. Can you handle AutoCAD files in either DWG or DXF format?
Bob C.
 
Burl,
I can't tell from the prototype photos but I recall that the top of these tanks were sloped the same as the bottom. I used spot a corn syrup facility that got these cars on a daily basis, but there are slight differences between car manufactures. As a side note when these cars are spotted for unloading they are first connected to a steam line that heats up the car so the syrup will flow.
 
Discussion starter · #29 ·
Bob:

Half of the tank body is a 4” OD cylinder, 7.473” long, with a rotation such that one end is 0.207” lower than the other. Somewhere in the neighborhood of 1.6 degrees of rotation, so the sum total between both cylinders would be about 3.2 degrees.

The final OD of the model will be 4.138”, but I will have to build up that from a 4” OD tube.

I should be able to open DWG or DXF in Sketchup.
 
Discussion starter · #31 ·
After I stewed on it for a while, I realized I forgot to draw up the placards. They are probably too thin to print separately, and I got lazy, so I will have the whole mold box printed:

Image



I also figured out (by trial and error) that it is cheaper to have the ladders printed ten at a time, versus two at a time with the rest of the nylon parts:

Image



By doing this, I was able to keep the cost of the rest of the nylon printed parts under $60 per car. That's assuming Shapeways doesn't jack up the prices again on me.

I believe these to be the last of my revisions, so I placed an order for all the printed parts this morning, virtually ensuring Shapeways will have a sale tomorrow...
 
Discussion starter · #35 ·
While I'm waiting for my parts to come in, I'm making molds for the outer tank jacket. I'm trying to get the ripples a little more subtle for this car than I would for a boxcar, or a hopper, or something where the sheet metal is flat. I'm thinking the outer tank jacket will be thicker sheet metal on the prototype and not as prone to "oil can".

Image
 
Burl,
Are you planning on a flat wrapping for each car? Or is the mold going to be a circular mold? These tanks have quite thick insulation for the heating, and steam lines, so that outer layer might be thinner than you think. I don't recall seeing any more or any less damage than regular boxcars, but I wasn't ever planning really close attention either.
Craig
 
I'll throw in my thoughts on tank cars..

I have ...a couple tank cars I started years ago...the basic structure is built from heavy PVC pipe... couplings ...& and rounded over caps for ends..
My thoughts were to over lay these base tubes with sections of 0.010" sheet to create the offset overlaps often seen on tank cars..

My other observation..and thus comparision to your thoughts Burl is these outer coverings are not of a base structural make-up...the main inner tank does this..as such there would not be any or very little wrinkling or stress induced in the outer skins...on box cars & hoppers, the thin side skins are part of the load carrying design...and become distorted under loads as a whole with the entire structure. This is similar to those outer coverings on a boiler of a steam engine...

Sure...mishaps occur....dents are left behind...but I'm not seeing a lot of the wrinkly waves seen on other cars..

Keep striving onward...thanks for your incredible projects Burl.

Dirk
 
Well.....so I went picture wandering....

Looked at many styles of tank cars....from various random owners..

What I saw is interesting...not unlike what I get to actually see rolling by...

Regardless of wrapper design...I saw no damage or flexing or waves or deformation on any car I looked at..
I saw one end cap ...ever so slightly punched... the result of some small blunt object...small dimples at best!

While most cars I observe fall in the stepped overlap skin group...I know some wrappers must be built using a butt-joint design....either way...the only real significant thing might have been circular deformation at these seams.
The step-overlaps are assembled by placing the first wrapper over the end cap, next installed is the third wrapper, followed by the second wrapper...over lapping..and sitting higher by the skins thickness...over both seams on the 1st n 3rd wrappers...and so on....
These seams have a tendancy to shrink and pull inwards in their completed form...slightly....

Cars for the most part do not show much damage or stress aging from use like most other pieces of equipment do.

Dirk
 
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