Teaching An Old Lathe New Tricks With A Programmable Power Feed

October 4, 2020 by Adam Zeloof 17 Comments

Ask anybody whose spent time standing in front of a mill or lathe and they’ll tell you that some operations can get tedious. When you need to turn down a stainless rod by 1/4″ in 0.030″ increments, you get a lot of time to reflect on why you didn’t just buy the right size stock as you crank the wheel back and forth. That’s where the lead screw comes in — most lathes have a gear-driven lead screw that can be used to actuate the z-axis ( the one which travels parallel to the axis of rotation). It’s no CNC, but this type of gearing makes life easier and it’s been around for a long time.

[Tony Goacher] took this idea a few steps further when he created the Leadscrew Buddy. He coupled a beautiful 1949 Myford lathe with an Arduino, a stepper motor, and a handful of buttons to add some really useful capabilities to the antique machine. By decoupling the lead screw from the lathe’s gearbox and actuating it via a stepper motor, he achieved a much more granular variable feed speed.

If that’s not enough, [Tony] used a rotary encoder to display the cutting tool’s position on a home-built Digital Readout (DRO). The pièce de résistance is a “goto” command. Once [Tony] sets a home position, he can command the z-axis to travel to a set point at a given speed. Not only does this make turning easier, but it makes the process more repeatable and yields a smoother finish on the part.

These features may not seem so alien to those used to working with modern CNC lathes, but to the vast majority of us garage machinists, [Tony]’s implementation is an exciting look at how we can step up our turning game. It also fits nicely within the spectrum of lathe projects we’ve seen here at Hackaday- from the ultra low-tech to the ludicrously-precise.

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True Craftsmanship: Pneumatic Powered Drone Wasn’t Made To Fly

August 10, 2020 by Danie Conradie 16 Comments

From time to time it’s good to be reminded that mechanical engineering can also be art. [José Manuel Hermo Barreiro], also known as [Patelo], is a retired naval mechanic with a love for scale model engines. Using only basic tools and a lathe, he has built a non-flying hexacopter display model, each propeller turned by a tiny single cylinder motor that runs on compressed air. From the tiny components of the valve systems, the brass framed acrylic windows into the crankcases, and the persistence of vision disc on the exhaust, the attention to detail is breathtaking.

One of the six hand crafted pneumatic motors

[Patelo] started the project on paper, and created a set of detailed hand-drawn blueprints to work from. Sadly a large part of the build took place during lockdown, and was not filmed, but we still get to see some work on a crankcase, connecting rod, camshaft, propellers, flywheel, and exhaust tubes. It is very clear that [Patelo] knows his way around his lathe very well, and is very creative with custom tools and jigs. The beautiful machine took approximately 1,560 hours to build, consists of 265 individually made parts held together with 362 screws.

We previously featured tiny V-12 engine that [Patelo] built around 2012. At that time he was 72 years of age, which means he should be around 80 now. We can only hope to come to emulate him one day, and that we get to see more of what comes out of his workshop. Hats off to you, sir.

Turning A Waterjet Cutter Into A Wood Lathe, For No Reason

July 9, 2020 by Dan Maloney 30 Comments

On the shortlist of dream tools for most metalworkers is a waterjet cutter, a CNC tool that uses insanely high-pressure water mixed with abrasive grit to blast sheet metal into intricate shapes. On exactly nobody’s list is this attachment that turns a waterjet cutter into a lathe, and with good reason, as we’ll see.

This one comes to us by way of the Waterjet Channel, because of course there’s a channel dedicated to waterjet cutting. The idea is a riff on fixtures that allow a waterjet cutter (or a plasma cutter) to be used on tubes and other round stock. This fixture was thrown together from scrap and uses an electric drill to rotate a wood blank between centers on the bed of the waterjet, with the goal of carving a baseball bat by rotating the blank while the waterjet carves out the profile.

The first attempt, using an entirely inappropriate but easily cut blank of cedar, wasn’t great. The force of the water hitting the wood was enough to stall the drill; the remedy was to hog out as much material as possible from the blank before spinning up for the finish cut. That worked well enough to commit to an ash bat blank, which was much harder to cut but still worked well enough to make a decent bat.

Of course it makes zero sense to use a machine tool costing multiple hundreds of thousands of dollars to machine baseball bats, but it was a fun exercise. And it only shows how far we’ve come with lathes since the 18th-century frontier’s foot-powered version of the Queen of the Machine Shop.

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Build A Lathe Like It’s 1777

June 29, 2020 by Tom Nardi 22 Comments

We’ve seen quite a few scratch built lathes here at Hackaday, but none quite like the handcrafted pole lathe put together by [Jon Townsend] and his band of Merry Men as part of their effort to build a period-accurate 18th century log cabin homestead. With the exception of a few metal spikes here and there, everything is made out of lumber harvested from the forest around them.

The lathe is designed to be a permanent structure on the homestead, with two poles driven into the ground to serve as legs. Two rails, made of a split log, are then mounted between them. The movable components of the lathe, known as “puppets” in the parlance of the day, are cut so they fit tightly between the rails but can still be moved back and forth depending on the size of the work piece. With two metal spikes serving as a spindle, the log to be turned down is inserted between the puppets, and wedges are used to lock everything in place.

So that’s the easy part. But how do you spin it? The operator uses a foot pedal attached to a piece of rope that’s been wound around the log and attached to a slender pole cantilevered out over the lathe. By adjusting the length and angle of this pole, the user can set the amount of force it takes to depress the pedal. When the pedal is pushed down the log will spin one way, and when the pole pulls the pedal back up, it will spin the other.

Since the tools only cut in one direction, the user has to keep letting the pressure off when the log spins back around. The fact that the work piece isn’t continuously rotating in the same direction makes this very slow going, but of course, everything was just a bit slower back in the 18th century.

So now that we’ve seen lathes made from wood, intricately cut slabs of stone, and a grab bag of junkyard parts, there’s only one question left. Why do you still not have one?

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Turn By Wire Is A Machinist’s Sixth Sense

March 24, 2020 by Sonya Vasquez 14 Comments

It’s hard not to be a little intimidated by the squeaks and whirs that come with your first journey into a machine shop. Here, skilled machinists pilot giant hunks of cast iron that turn metals into piles of chips to yield beautiful parts. But what if machine tools themselves didn’t have to seem so scary. What if using them could feel a bit more intuitive, even, dare we say, natural from the get-go?

Enter Turn by Wire, a unique set of force feedback and machine control concepts applied to a lathe brought to you by researchers [Rundong Tian], [Vedant Saran], [Mareike Kritzler], [Florian Michahelles], and [Eric Paulos] at Berkelely.

Turn by Wire vastly reimagines the relationship between a user’s control inputs and the machine outputs in two ways: (1) by changing the mapping between the hand cranks and machine movements and (2) by changing the haptic feedback felt by the machinist. Since both of these interactions can be defined programmatically, the researchers created three unique ways of interacting with the lathe. First, by defining a tool path in the graphic user interface (GUI), the machinist can use a single hand crank to step forward and back in time along that toolpath. Second, by applying virtual guidelines in the GUI, both the machine and the hand cranks will physically snap to the guide lines when they are sufficiently close. Finally, the hand cranks can be used to teach the machinist a technique by adding resistive forces into the hand cranks depending on movement while a machinist is stepping through a process like peck drilling.

This is a great example of [Tom Knight’s] “just wrap a computer around it!” as mentioned by [Bunnie Huang] when we featured the IQ Motor Modules. It’s a powerful example of how putting a computer between the controls and the machine can correct for real world imperfections, be they in the mechanics of the machine of the operator. For the curious, have a look at [Rundong’s] paper published at UIST and [Vedant’s] master’s thesis.

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Screwy Math For Super Fine Adjustments: Differential Screws

March 21, 2020 by Danie Conradie 38 Comments

For any sort of precision machine, precision adjustability is required. For the hacker this usually involves an adjustment screw, where the accuracy is determined by the thread pitch. This was not good enough for [Mark Rehorst] who wanted adjustment down to 10 μm for his 3D printer’s optical end-stop, so he made himself a differential adjustment screw.

Tiny adjustment can be made to the green block due to the thread pitch differences

Differential screws work by having two threads with a slightly different pitch on the same shaft. A nut on each section of thread is prevented from rotating in relation to the other, and when the screw is turned their relative position will change only as much as the difference between the two thread pitches.

The differential screw in this case started life as a normal M5 bolt with a 0.8 mm thread pitch. [Mark] machined and threaded section of the bolt down to a M4 x 0.7 mm thread. This means he can get 0.1 mm (100 μm) of adjustment per full rotation. By turning the bolt 1/10 rotation, the relative movement comes down to 10 μm.

This mechanism is not new, originating from at least 1817. If you need fine adjustments on a budget, it’s a very elegant way to achieve it and you don’t even need a lathe to make your own. You can partially drill and tap a coupling nut, or make a 3D printed adapter to connect two bolts.

Fabricating precision tools on a budget is challenging but not impossible. We’ve seen some interesting graphite air bearings, as well as a 3D printed microscope with a precision adjustable stage.

This V8 Makes A Shocking Amount Of Power

March 20, 2020 by Bryan Cockfield 32 Comments

As a work of art, solenoid engines are an impressive display of electromagnetics in action. There is limited practical use for them though, so usually they are relegated to that realm and remain display pieces. This one from [Emiel] certainly looks like a work of art, too. It has eight solenoids, mimicking the look and internal workings of a traditional V8.

There’s a lot that has to go on to coordinate this many cylinders. Like an internal combustion engine, it takes precise timing in order to make sure that the “pistons” trigger in the correct order without interfering with each other through the shared driveshaft. For that, [Emiel] built two different circuit boards, one to control the firing of each solenoid and another to give positional feedback for the shaft. That’s all put inside a CNC-machined engine block, complete with custom-built connecting rods and shafts.

If you think this looks familiar, it’s because [Emiel] has become somewhat of an expert in the solenoid engine realm. He started off with a how-to for a single piston engine, then stepped it up with a V4 design after that. That leaves us wondering how many pistons the next design will have. Perhaps a solenoid version of the Volkswagen W12?

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