Metal Box Project
- Relevant Skills: Metalworking, Precision Measurement, Brazing, Layout, Cutting, Shaping
- Materials: Cold Rolled 22 Gauge Steel, Brass Braze
- Tools and Equipment: Combination Square, Scribe, Dykem® Steel Blue Layout Fluid, DeWalt® Angle Grinder, Hole Punch Machine, Alphabetical Stamps, Hand Metal Shear, Brazing Tool, Shear, Brake
Situation
In our advanced machine tool class, we were tasked with fabricating a metal box using cold rolled 22 gauge steel. This project was designed to develop our skills in precision metalworking, including measuring, cutting, shaping, and brazing. The assignment simulated a real-world manufacturing scenario where accuracy and attention to detail are critical.
Task
The specific task was to construct a metal box by following a comprehensive set of manufacturing procedures. The steps involved precise layout, cutting, bending, and brazing to create a functional and aesthetically pleasing product. The final box needed to meet specified dimensions and quality standards, demonstrating proficiency in metalworking techniques.
Action
- Preparation: Applied Dykem® Steel Blue Layout Fluid, used combination square with scribe for accurate layout.
- Cutting: Resized the sheet using hand metal shear, marked additional cuts and cut to specified dimensions.
- Hole Punching: Used hole punch machine for precise holes as per blueprint.
- Bending: Employed brake machine to bend metal, creating rounded edges and forming the box shape.
- Brazing: Used brazing tools for secure, clean joints, controlled brazing temperature to avoid warping.
- Finishing: Filed and ground rough edges with DeWalt® angle grinder, stamped name with alphabetical stamps, applied clear protective coat.
Result
The final product was a well-constructed metal box that met all the specified dimensions and quality standards. This project significantly enhanced my skills in metal layout, cutting, bending, and brazing, providing a thorough understanding of the entire metalworking process. The experience improved my attention to detail, precision, and ability to follow complex procedures accurately. The completed box demonstrated my capability to produce high-quality metalwork with a professional finish.
Small Aluminum Hammer Project
- Relevant Skills: Machining, Precision Measurement, Knurling, Finishing
- Materials: Aluminum
- Tools and Equipment: Dykem® Steel Blue Layout Fluid, Alphabetical Stamps, Portable Band Saw, Tap and Die Tools, Knurling Clamp, Metal Lathe, Drill Press, Sandpaper, Scribe, Vice
Situation
The second project in our machine tool class involved creating a small aluminum hammer. This task aimed to further develop our machining skills, focusing on precision cutting, shaping, and finishing of aluminum components. The project emphasized the importance of accuracy, craftsmanship, and attention to detail in producing a functional tool.
Task
Our objective was to fabricate a functional and aesthetically pleasing aluminum hammer, consisting of a handle and a hammerhead, by following a series of detailed manufacturing steps. The project required the use of various tools and machinery to cut, machine, and assemble the hammer parts, ensuring a high-quality finish and precision.
Action
- Preparation: Cut aluminum stock for handle and hammerhead using portable band saw, machined cut sides to smooth finish.
- Shaping the Shank: Applied Dykem® Steel Blue Layout Fluid, machined shank on lathe to ½ inch diameter, created threads with tap and die tools.
- Drilling the Hammerhead: Drilled 2-inch hole with drill press, created flat surface for shank, set threads inside hammerhead.
- Finishing: Sanded surfaces on lathe, knurled grip on handle, optionally added unique lines, stamped initials on handle.
Result
The completed aluminum hammer was both functional and visually appealing, demonstrating a high level of craftsmanship and attention to detail. This project provided valuable experience in using machining tools such as the lathe, drill press, and band saw, and improved my skills in precision measurement and finishing techniques. The finished hammer reflected my ability to produce high-quality, precise, and aesthetically pleasing metalwork. The project also reinforced the importance of planning, precision, and careful execution in machining and fabrication.
