The Manufacture of 3rd Year Projects (describe processes) Flashcards
What are the 8 steps of the picture frame project?
- Casting the pewter bse
- Drilling the hole
- Cutting the steel bar
- Putting a screw thread on the bar
- Brazing the steel ball onto the bar
- Dip coating the handle for the stand
- Filing and polishing the base
- Assembling the final product
Picture Frame Project:
How did we cast the pewter base of the picture frame?
Molten pewter (260°C) is poured into a mould and then left to set. Then it is cut into 3x 50mm pieces (to make 3 picture frames).
Picture Frame Project:
How did we drill a hole in the base of the picture frame?
Use a steel rule to find the centre of the back of the stand. Then use a hammer to create an indent on the dot. Lastly drill a hole using the pillar drill.
Picture Frame Project:
How did we cut a steel bar for the picture frame?
Use a saw to cut 50mm off a metal bar. Then file the end to a point.
Picture Frame Project:
How did we put a screw thread on a steel bar for the picture frame?
Use a saw to cut 50mm off a metal bar. Then file the end to a point.
Picture Frame Project:
How did we braze the steel ball onto the bar for the handle of the picture frame?
Use the CNC Boxford Lathe to make the mild steel ball and then heat the ball and the bar. Then braze them together with copper (using the very hot green flame whilst wearing proctive goggles and apron).
Picture Frame Project:
How did we dip coat the handle of the picture frame?
File the ball and the bar until they are shiny and then heat with a blow torch. Then dip into the plastic powder and tap the stick you are holding it with on the side to get the excess off. Leave to set.
Picture Frame Project:
How did we file and polish the base of the picture frame?
File the pewter base surfaces using a rasp (a course file) first, then a file, then the wet and dry paper types (starting with the roughest and getting gradually smoother). Then use polish and a cloth to make them shiny.
Picture Frame Project:
How did we assemble the final product?
Use the laser cutter to cut out your final design that you made on the computer on Techsoft 2D Design, then put it into your frame and secure it in place with the screw.
What are the 4 stages of making the Memphis Clock?
- Designing the clock
- Gluing together
- Drilling the hole
- Putting in the mechanism and stand
Memphis Clock Project
How did we design the clock?
We used TechSoft 2D Design to design our clock. We had to create a view of
* how the pieces would look when put together (- to show they would fit together),
* when they were split apart (- so that they could be laser cut),
* just the outline of them (-so the background could be laser cut),
* and how it would look coloured in (- to know what colours each piece should be).
Memphis Clock Project
How did we glue together the clock?
After the pieces had been cut, we used [don’t know the name] glue to glue the seperate pieces together, onto the clear background.
Memphis Clock Project
How did we drill the hole in the clock?
After the glue had dried, we used a pillar drill fitted with a special attatchment [ask name] to drill a hole in the acrylic (approx 7mm diameter) which could fit the mechanism in.
Memphis Clock Project
How did we put the mechanism in the clock and put the stand on?
Slot the mechanism through the hole, leaving the black box secured on the back (and out of sight), then put on (in this order) the hour hand, the minute hand, and the second hand. Put in the batteries to start the clock.
Optionally, use the [strip heater] to heat a strip of a clear piece of acrylic, then bend it into the shape of a stand and hold it until it cools and sets.
