When machining metal, it is important to know how fast the cutting tool is traveling in relation to the surface of the part being machined. This amount is called the ‘Surface Speed’. There are Surface Speed standards for cutting different types of materials and it is good practice to stick with those standards in order to end up with a good surface finish as well as maximizing tool life. On a lathe, for example, having a known target Surface Speed in mind as well as a part finish diameter, it is possible to calculate the necessary spindle speed.
Hobbyist [Paul] wanted a method of measuring his lathe’s spindle speed. Since spindle speed is measured in RPM, it made complete sense to install a tachometer. After browsing eBay for a bit he found one for about $20. His purchase came with the numeric LED display, a mounting bezel and the all important hall effect sensor. The Hall effect sensor measures changes in a magnetic field and in turn varies its output voltage. [Paul] fabbed up an aluminum bracket that supports the sensor just off of the rear of the lathe spindle. A magnet was then glued to the outside diameter of the spindle below the sensor. The once per revolution signal is generated every time the magnet passes the sensor while the lathe is running. The display was mounted to the lathe near eye height by means of another aluminum bracket and case.
After a little work, [Paul] can now keep a close eye on his spindle speed with a quick glance over at his new tachometer display while he’s turning those perfect parts! If this project tickles your fancy, you may want to check out this fantastic DIY tachometer or this one that uses a soundcard.
[Connor] was working on a project for his college manufacturing class when he came up with the idea for this sleek desk lamp. As a college student, he’s not fond of having his papers glowing brightly in front of him at night. This lamp takes care of the problem by adjusting the color temperature based on the position of the sun. It also contains a capacitive touch sensor to adjust the brightness without the need for buttons with moving parts.
The base is made from two sheets of aluminum and a bar of aluminum. These were cut and milled to the final shape. [Connor] found a nice DC barrel jack from Jameco that fits nicely with this design. The head of the lamp was made from another piece of aluminum bar stock. All of the aluminum pieces are held together with brass screws.
A slot was milled out of the bottom of the head-piece to make room for an LED strip and a piece of 1/8″ acrylic. This piece of acrylic acts as a light diffuser. Another piece of acrylic was cut and added to the bottom of the base of the lamp. This makes for a nice glowing outline around the bottom that gives it an almost futuristic look.
The capacitive touch sensor is a pretty simple circuit. [Connor] used the Arduino capacitive touch sensor library to make his life a bit easier. The electronic circuit really only requires a single resistor between two Arduino pins. One of the pins is also attached to the aluminum body of the lamp. Now simply touching the lamp body allows [Connor] to adjust the brightness of the lamp.
[Connor] ended up using an Electric Imp to track the sun. The Imp uses the wunderground API to connect to the weather site and track the sun’s location. In the earlier parts of the day, the LED colors are cooler and have more blues. In the evening when the sun is setting or has already set, the lights turn more red and warm. This is easier on the eyes when you are hunched over your desk studying for your next exam. The end result is not only functional, but also looks like something you might find at that fancy gadget store in your local shopping mall.
A steady rest is a tool for a lathe, enabling a machinist to make deep cuts in long, slender stock, bore out thin pieces of metal, and generally keeps thin stuff straight. Unlike a tool that follows the cutter, a steady rest is firmly attached to the bed of a lathe. [Josh]’s lathe didn’t come with a steady rest, and he can’t just get parts for it. No problem, then: he already has a lathe, mill, and some metal, so why not make the base for one from scratch?
[Josh] was able to find the actual steady rest from an online dealer, but it wasn’t made for his lathe. This presented a problem when attaching it to his machine: because each steady rest must fit into the bed of the lathe, he would need a custom bracket. With the help of a rather large mill, [Josh] faced off all the sides of a piece of steel and cut a 45 degree groove. To make this base level, [Josh] put one side of the base on the lathe, put a dial micrometer on the tool post, and got an accurate reading of how much metal to take off the uncut side.
With the steady rest bolted onto the lathe, [Josh] turned a rod and found he was off by about 0.002″. To machinists, that’s not great, but for a quick project it’s fantastic. Either way, [Josh] really needed a steady rest, and if it works, you really can’t complain.
Continue reading “Adding a Steady Rest to a Lathe”
We’ve covered many thermoelectric beverage coolers in the past, but none come close to the insane power of the AbsolutZero. [Ilan Moyer] set out to design a beverage cooler that chills a drink from room temperature to 5 degrees Celsius as quickly as possible, and it looks like he succeeded. The AbsolutZero consumes around 2.5kW of power and runs 8 water-cooled thermoelectric modules to quickly chill a drink.
[Ilan] put his machinist skills to work and fabricated many custom parts for this build. He machined water blocks for each thermoelectric cooler out of solid copper which draw heat away from each thermoelectric cooler. He also fabricated his own bus bars to handle the 200A+ of current the system draws. To transfer heat from the beverage to the thermoelectric modules, he turned and milled a heat spreader that perfectly fits a can of any beverage.
[Ilan]’s design uses a closed-loop water cooling system and 4 radiators to dissipate all of the heat the system produces, which is quite a lot: thermoelectric modules are typically only 10-15% efficient. The whole design is buttoned up in a custom polycarbonate enclosure with a carrying handle so you can conveniently lug the massive setup wherever quickly chilled beverages are needed. Be sure to check out [Ilan]’s build photos to see his excellent machining work.
Thanks for the tip, [Stefan].
Have you been let down by the inadequate performance of a hand dryer? We know that feel. [tesla500] recently installed a centralized compressed air system and decided he might as well do something interesting it, so he built an ultra-powerful hand dryer that rivals the performance of any hand dryer on the market.
[tesla500] set out to make a clone of the Dyson Airblade. He started out with a simple prototype out of milled aluminum with one nozzle. Even with just one nozzle the hand dryer performed incredibly well. Next he designed a Solidworks model with a smaller nozzle gap (50um) and 4 total nozzles which has even better performance and emulates the airflow of the Airblade.
The dryer was originally controlled with a foot-activated pneumatic valve, but it severely restricted airflow. [tesla500] decided to use a 3/8″ solenoid valve instead, which solved the airflow restriction. According to [tesla500], the dryer works even better than the Airblade when running at full pressure, although he notes that you might need to watch out if you have any open wounds on your hands.
In the depths of YouTube there are still some jewels to be found. [Keith Fenner] is one of them. [Keith] owns Turn Wright Machine Works in Cape Cod, MA. From his small shop, He works on everything from sailboats to heavy equipment.
[Keith] describes himself as “An artist, and a jobber, 36 years in the trade”. We think he could add teacher to that list, as we’ve learned quite a bit about machining from his Youtube channel.
One of the interesting things about [Keith] is his delivery on camera. He makes the viewer feel like an apprentice machinist working alongside him. Rather than carefully setup shots with graphics, [Keith] narrates as he works paying jobs. He also has no problem showing us his mistakes – and recovery from them, as well as his victories.
The main tools at Turn Wright are the lathe and mill, but [Keith] isn’t old fashioned by any means. He has a complete PlasmaCAM setup and isn’t afraid to do a little computer work.
Most of [Keith’s] projects are broken up into several videos. One of our favorites is “So you broke it off in your hole”. In this series [Keith] shows what it takes to get a broken screw extractor (or EZ Out) out of a large diesel turbo. Get a feeling for what [Keith] has to offer with his “Day in the LIfe” video after the break.
Continue reading “Learn machining from an old school metal master”
What in the heck is an Orrery? If you’re looking at the image above we’re sure you’ve already figured it out (kudos to the big brains that knew the word). For those that don’t get it, an Orrery is a mechanical device that represents the movements of planets and moons. We never thought of building one ourselves. After seeing the machining process for what’s shown above we’re not sure if we’re excited, or scared off by all the work that went into it.
You might want to bust out the Chromecast and hit the sofa for this one. There are dozens of YouTube videos showing the build. From cutting sheet stock into round slugs, to making teeth, teeth, teeth, and more teeth it’s not just the gears that go into this one. You’re also going to needs the orbs themselves.
We have fond (perhaps scary) memories of the first time we saw an Orrery as a part of the set in The Dark Crystal.
Continue reading “Machining an Orrery”