Big homemade lathe

Heavy Metal Lathe Build Doesn’t Spare The Steel

October 27, 2021 by 22 Comments

It’s common wisdom that the lathe is the essential machine tool, and the only one that can make copies of itself. While we won’t argue the primacy of the lathe in the machine shop, this scratch-built, heavy-duty lathe gives the lie to the latter argument — almost.

We’re used to seeing homebrew lathes, of course, and we’ve featured more than a few of them before. But two things make [Jornt]’s build stand out: how few specialized tools were needed to build it, and the sheer size and bulk of the finished product. Where most homebrew lathes tend to be the bench top variety and feature cast aluminum parts, [Jornt] went with steel for his build, and a lot of it. The base and bed of the machine are welded from scrap steel I-beams, and the ways are made from angle iron that has been ground flat with a clever jig to hold an angle grinder. The angle grinder plays a prominent role in the build, as do simple tools like a hand drill, files, and a welder — and yes, the unfinished lathe itself, which was used to bore out the bearing blocks for the headstock.

The completed lathe, powered by a treadmill motor in a way that [Jeremy Fielding] would no doubt endorse, comes in at a beefy 450 kg. It honestly looks like something you could buy from a catalog, and has most of the features of commercial machines. One thing we’d love to see on this lathe is the electronic lead screw that [James Clough] developed for his off-the-shelf lathe.

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$10 000 Physics Wager Settles The Debate On Sailing Downwind Faster Than The Wind

July 2, 2021 by 95 Comments

By now, many of you have seen the video of [Rick Cavallaro]’s Blackbird, the controversial wind-powered land vehicle that can outrun the wind. The video has led to a high-profile $10 000 wager between [Derek Muller] aka [Veritasium] and [Alex Kusenko], a professor of physics from UCLA. [Veritasium] won the wager with the help of a scale model built by [Xyla Foxlin], and you need to watch the videos after the break for some excellent lessons in physics, engineering, and civilized debate.

After seeing [Veritasium]’s video on Blackbird, [Professor Kusenko] contacted him and said the performance claims and explanation were incorrect. After a bit of debate [Veritasium] proposed a wager on the matter, which [Professor Kusenko] accepted, and it was made official with a written agreement witnessed by [Neil deGrasse Tyson], [Bill Nye], and [Sean Carrol]. From the start, it was agreed that the entire debate would be made public.

[Professor Kusenko] made a very thorough and convincing argument, backed by calculations, against the claims in the video. He claimed the observations were due to a combination of gusty winds, a vertical wind gradient. He was convinced and that the vehicle would not be able to maintain a speed higher than the wind, directly downwind. By [Veritasium]’s own admittance, his original video could have contained more details and proof of performance claims of the Blackbird vehicle. He added these to the latest video and included two model demonstrations. The model that brought the concept home for us is at 13:46 in the video, and substitutes the propeller for a large wheel being driven by a piece of lumber being bushed across it. The second model, built by [Xyla Foxlin] was designed to demonstrate the concept on a treadmill. The 4th version of [Xyla]’s model was the first to be successful after she found out from [Rick Cavallaro] that the key design detail is the Vehicle Speed Ratio, which must be 0.7 or less. It is the pitch of the propeller divided by the circumference of the driven wheel, assuming a 1:1 gear ratio. All the 3D files and details are available if you want to build your own downwind cart. Continue reading “$10 000 Physics Wager Settles The Debate On Sailing Downwind Faster Than The Wind” →

ISS Artificial Gravity Study Shows Promise For Long Duration Spaceflight

June 8, 2021 by 105 Comments

The International Space Station is humanity’s most expensive gym membership.

Since the earliest days of human spaceflight, it’s been understood that longer trips away from Earth’s gravity can have a detrimental effect on an astronaut’s body. Floating weightless invariably leads to significantly reduced muscle mass in the same way that a patient’s muscles can atrophy if they spend too much time laying in bed. With no gravity to constantly fight against, an astronauts legs, back, and neck muscles will weaken from disuse in as little as a week. While this may not pose an immediate problem during spaceflight, astronauts landing back on Earth in this physically diminished state are at a higher risk of injury.

Luckily this problem can be largely mitigated with rigorous exercise, and any orbiting vessel spacious enough to hold human occupants for weeks or months will by necessity have enough internal volume to outfit it with basic exercise equipment such as a treadmill or a resistance machine. In practice, every space station since the Soviet Union’s Salyut 1 in 1971 has featured some way for its occupants to workout while in orbit. It’s no replacement for being on Earth, as astronauts still return home weaker than when they left, but it’s proven to be the most practical approach to combating the debilitating aspects of long duration spaceflight.

Early NASA concept for creating artificial gravity.

Of course, there’s an obvious problem with this: every hour spent exercising in space is an hour that could be better spent doing research or performing maintenance on the spacecraft. Given the incredible cost of not just putting a human into orbit, but keeping them there long-term, time is very literally money. Which brings us back to my original point: astronauts spending two or more hours each day on the International Space Station’s various pieces of exercise equipment just to stave off muscle loss make it the world’s most expensive gym membership.

The ideal solution, it’s been argued, is to design future spacecraft with the ability to impart some degree of artificial gravity on its passengers through centripetal force. The technique is simple enough: just rotate the craft along its axis and the crew will “stick” to the inside of the hull. Unfortunately, simulating Earth-like gravity in this way would require the vessel to either be far larger than anything humanity has ever launched into space, or rotate at a dangerously high speed. That’s a lot of risk to take on for what’s ultimately just a theory.

But a recent paper from the University of Tsukuba in Japan may represent the first real steps towards the development of practical artificial gravity systems aboard crewed spacecraft. While their study focused on mice rather than humans, the results should go a long way to codifying what until now was largely the stuff of science fiction.

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The Simplest Wind Turbine Is The Most Satisfying

April 7, 2021 by 37 Comments

Sometimes there’s a satisfaction to be found not in the more complex projects but the simplest ones. We’ve featured wind turbines of all types here at Hackaday over the years, but HowToLou’s one is probably one of the least sophisticated. That notwithstanding, it does its job admirably, and provides a handy reminder of a parts source many of us might have overlooked.

At its heart is a motor from an exercise treadmill, which appears to be quite a powerful DC motor so that’s a source worth noting away for any future projects. To that he attaches the blades from a desk fan, and when placed outdoors on a windy day it generates enough power to run an LED head torch and charge his phone.

Of course, this most basic of wind turbines is not displaying its true potential in the video below the break. Were it mounted in a high position free from ground based wind obstacles it would no doubt catch a lot more wind, and in particular were it hooked up to a charge controller and a battery it could provide a much more useful power source. Then you could start optimizing fan blade designs… But this is a fun project that isn’t trying to masquerade as anything sophisticated, and it still has that potential.

This isn’t the first such simple turbine we’ve brought you.

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Force Feedback Mouse Really Shakes Things Up

May 17, 2020 by 21 Comments

This is a very exciting time for those who like to spend their downtime exploring virtual worlds. The graphics in some big-budget titles are easily approaching photorealism, and immersive multi-channel sound can really make you believe you’ve been transported to another place or time. With another generation or two of GPU development and VR hardware, the line between gaming and reality is bound to get awful blurry.

That said, we’re still a far way off from the holodeck aboard the Enterprise. A high-end PC and the latest in VR can fool your eyes and ears, but that still leaves your other senses out of the fun. That’s why [Jatin Patel] has developed this clever force-feedback mouse using an array of solenoids.

The idea is pretty simple: a Python program on the computer listens for mouse click events, and tells an attached Arduino to fire off the solenoids when the player pulls the virtual trigger. It’s naturally not a perfect system, as it would seem that clicking in the game’s menus would also start your “gun” firing. But as you can see in the video after the break, when it works, it works very well. The moving solenoids don’t just vibrate the mouse around, the metallic clacking actually accentuates the gun sound effects from the game.

With this kind of tactile feedback and an omnidirectional treadmill to keep us moving, we’d be pretty close to fooling our senses into thinking we’re actually somewhere else. Which frankly, sounds quite appealing right about now.

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Scrapyard Milling Machine Gets Work Done On A Budget

September 1, 2019 by 22 Comments

Which to buy first, a lathe or a mill? It’s a tough question for the aspiring home machinist with limited funds to spend on machine tools, but of course the correct answer is a lathe. With a lathe, we are told, all other machine tools can be built, including a milling machine. Granted that might be a slight  exaggeration, but [Maximum DIY] was still able to use his budget-blowing lathe to make a decent milling machine mostly from scrap.

Details are a bit sparse in the forum post, but there’s enough there and in the video after the break to be mightily impressed with the build. Unlike many DIY mills that are basically modified drill presses, [Maximum DIY] started with things like a scrapped bench grinder pedestal and surplus steel tubing. The spindle motor is from a paint sprayer and the Z-axis power feed is a treadmill incline motor. The compound table was a little too hard to make, so the purchased table was fitted with windshield wiper motor power feeds.

Therein lies perhaps the most clever hack in this build: the use of a plain old deep 19mm socket as a clutch for the power feeds. The 12-point socket slides on the square shaft of the wiper motor to engage the drive screw for the compound table – simple and bulletproof.

To be sure, the finished mill is far from perfect. It looks like it needs more mass to quell vibration, and those open drive pulleys are a little nerve wracking. But it seems to work well, and really, any mill is better than no mill. Of course, if you’re flush with cash and want to buy a mill instead of making one, this buyer’s guide should help.

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Another Take On Harvesting Energy While Walking

July 19, 2019 by 17 Comments

Harvesting energy from the human body may sound scary, but fortunately a Matrix-style setup exists only as a cinematic fiction. Instead a typical path lies in external contraptions that use the body’s natural motions to drive a small generator, a bit of flexible piezo material, and so on. A popular target for harvesting the body’s kinetic energy is the knee joint, as this has a comparatively large range of motion and is fairly easy to use.

Thus a team from Hong Kong university opted to pick this part of the human anatomy for their experiment as well. While at first glance their results do not seem particularly impressive, with up to 1.6 mW of power generated, a look at their published results in the Applied Physics Letters journal showed their reasoning behind this setup. While one generator-based setup referenced produces on average 4.8 Watt of power, the device itself weighs 1.6 kg and increases the rate at which the person wearing it burns calories by a significant amount.

The goal for this device was to have a way to generate significant amounts of power without having the user exerting themselves more than usual. This led to them using flexible piezoelectric composites, resulting in a weight of just 307 grams, based upon two M8514-P2 pieces (Smart Materials Corp. manufacturer). Tests with volunteers on a treadmill show that users do not burn more calories than without.

As with all piezo materials, they can flex a bit, but not too much, so a lot of time and effort went into calculating the optimal bend radius in different usage scenarios. While around 1 mW of power is not massive, it is a reliable source of power for individuals who do any amount of walking during the day and doesn’t require any effort beyond strapping the device onto one’s legs.