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Hackaday Links: December 22, 2024

Early Monday morning, while many of us will be putting the finishing touches — or just beginning, ahem — on our Christmas preparations, solar scientists will hold their collective breath as they wait for word from the Parker Solar Probe’s record-setting passage through the sun’s atmosphere. The probe, which has been in a highly elliptical solar orbit since its 2018 launch, has been getting occasional gravitational nudges by close encounters with Venus. This has moved the perihelion ever closer to the sun’s surface, and on Monday morning it will make its closest approach yet, a mere 6.1 million kilometers from the roiling photosphere. That will put it inside the corona, the sun’s extremely energetic atmosphere, which we normally only see during total eclipses. Traveling at almost 700,000 kilometers per hour, it won’t be there very long, and it’ll be doing everything it needs to do autonomously since the high-energy plasma of the corona and the eight-light-minute distance makes remote control impossible. It’ll be a few days before communications are re-established and the data downloaded, which will make a nice present for the solar science community to unwrap.

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DIY Lock Nuts

If you have a metal lathe just looking for some work, why not make your own lock nuts? That’s what [my mechanics insight] did when faced with a peculiar lock nut that needed replacing in a car. We can’t decide what we enjoyed more in the video you can watch below: the cross-section cut of a lock nut or the oddly calming videos of the new nut being turned on a lathe.

The mystery of the lock nut, though, isn’t how it works. The nylon insert is just a little too small for the bolt, and the bolt, being harder than nylon, taps a very close-fitting hole in the nylon as you tighten it. The real mystery is how that nylon got in there to start with.

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A 3D Printed, Open Source Lathe?

[Chris Borge] has spent the last few years creating some interesting 3D printed tools and recently has updated their 3D printable lathe design to make a few improvements. The idea was to 3D print the outer casing of the lathe in two parts, adding structural parts where needed to bolt on motors and tool holders, and then fill the whole thing with concrete for strength and rigidity.

Only a few parts to print

The printed base is initially held together with two lengths of studding, and a pile of bolts are passed through from below, mating with t-nuts on the top. 2020 extrusion is used for the motor mount. The headstock is held on with four thread rods inserted into coupling nuts in the base. The headstock unit is assembled separately, but similarly; 3D printed outer shell and long lengths of studding and bolts to hold it together. Decent-sized tapered roller bearings make an appearance, as some areas of a machine tool really cannot be skrimped. [Chris] explains that the headstock is separate because this part is most likely to fail, so it is removable, allowing it to be replaced.

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Lathe Outfitted With Electronic Gearbox

Running a metal lathe is not for the faint of heart. Without proper knowledge and preparation, these machines can quickly cause injury or destroy expensive stock, tools, or parts. The other major problem even for those with knowledge and preparedness is that some of their more niche capabilities, like cutting threads with a lead screw, can be tedious and complicated thanks to the change gear system found on some lathes. While these are useful tools for getting things done, [Not An Engineer] decided that there was a better way and got to work building an electronic gearbox to automate the task of the traditional mechanical change gear setup in this video.

What makes change gears so tricky is that they usually come as a set of many gears of different ratios, forcing the lathe operator to figure out the exact combination of gears needed to couple the spindle of the lathe to the feed screw at the precise ratio needed for cutting a specific thread pattern. It is possible to do this task but can be quite a headache. [Not An Engineer] first turned to an Arduino Nano to receive input from a rotary encoder connected to the shaft of the lathe and then instruct a motor to turn the feed screw at a set ratio.

The first major problem was that the Arduino was not nearly fast enough to catch every signal from the encoder, leading to a considerable amount of drift in the output of the motor. That was solved by upgrading to a Teensy 4.1 with a 600 MHz clock speed. There was still one other major hurdle to cross; the problem of controlling the motor smoothly when an odd ratio is selected. [Not An Engineer] used this algorithm to inspire some code, and with that and some custom hardware to attach everything to the lathe he has a working set of electronic change gears that never need to be changed again. And, if you don’t have a lathe at all but are looking to get started with one, you can always build your own from easily-sourced parts.

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This Tiny Steam Engine Takes A Watchmaker’s Skill To Build

When your steam engine build requires multiple microscopes, including those of the scanning electron variety, you know you’re building something really, really tiny.

All of the usual tiny superlatives and comparisons apply to [Chronova Engineering]’s latest effort — fits on a pencil eraser, don’t sneeze while you’re working on it or you’ll never find it. If we were to put the footprint of this engine into SMD context, we’d say it’s around a 2010 or so. As one would expect, the design is minimalistic, with no room for traditional bearings or valves. The piston and connecting rod are one piece, meaning the cylinder must pivot, which provides a clever way of switching between intake and exhaust. Tiny crankshaft, tiny flywheel. Everything you’d associate with a steam engine is there, but just barely.

The tooling needed to accomplish this feat is pretty impressive too. [Chronova] are no strangers to precision work, but this is a step beyond. Almost everything was done on a watchmaker’s lathe with a milling attachment and a microscope assist. For the main body of the engine, a pantograph engraving machine was enlisted to scale a 3D printed template down tenfold. Drill bits in the 0.3 mm range didn’t fare too well against annealed tool steel, which is where the scanning electron microscope came into play. It revealed brittle fractures in the carbide tool, which prompted a dive down the rabbit hole of micro-machining and a switch to high-speed steel tooling.

It all worked in the end, enough so that the engine managed 42,000 RPM on a test with compressed air. We eagerly await the equally tiny boiler for a live steam test.

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Tiny Orrery Is A Watchmaker’s Tour De Force

Six tiny gears, a few fancy pins, and some clever casting are what it takes to build this tiny orrery. And patience — a lot of patience, too.

As model solar systems go, this one is exceptionally small. Its maker, [Mike] from Chronova Engineering, says it measures about 20 mm across and qualifies as the smallest orrery around. We can’t officiate that claim, but we’re not going to argue with it either. It’s limited to the Sun-Earth-Moon system, and while not as complete as some other models we’ve seen, it’s still exquisitely detailed. The gears that keep the Moon rotating 12.4 times around the Earth for each rotation of our home planet around the Sun are tiny, and take an abundance of watchmaking skill to pull off.

The video below shows the whole process, which is absolutely entrancing to watch. There are some neat tricks on display, from milling out the arms of the main wheel using a powered tailstock spindle to casting the Sun from resin in a silicone mold. The final model, with the model Earth and Moon spinning around the Sun on delicate brass wheels, is a visual treat.

We’ve seen some interesting stuff from Chronova Engineering lately, including this bimetallic tea timer.

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No Lathe? Build Your Own

If you need to make round things, you probably need a lathe. Can you build one as nice as one you can buy? Probably not. But can you build one that will work and allow you to do more things than having no lathe at all? [Mikeandmertle] say absolutely! You can see the contraption in operation in the video below.

The build is decidedly functional-looking and only requires a few parts. Most of the components are unremarkable, save for a threaded bar, a metal pipe, some bearings, and a few threaded inserts. Well, there’s also a drill chuck and two lathe centers. Those don’t have to be very expensive, but they may well be the bulk of what you have to spend to make this project.

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