(MONDAY 2/22/16)
We finally started machining our first lightsaber!
Well, actually, we started machining a tool for the lathe's tailstock called a "center". The center is a cylindrical/cone like chunk of metal that is inserted into the tailstock.
Well, actually, we started machining a tool for the lathe's tailstock called a "center". The center is a cylindrical/cone like chunk of metal that is inserted into the tailstock.
The center's purpose is to stabilize and eliminate vibration from the workspace and the part being worked on. I'm sure you can figure out how it does this by looking at the above third slide.
Also visible on the third slide is the lightsaber with all its markings before machining. It'll look much different by the time we get working on it.
Also visible on the third slide is the lightsaber with all its markings before machining. It'll look much different by the time we get working on it.
(TUESDAY 2/23/16)
Today we were met with some unfortunate news. The center we made yesterday doesn't work well enough for what we need. The piece fits and all, but the friction created by it is ridiculous, and cutting with it attached wouldn't be any better for us because of the possible metal warping that would ensue. Scott decided that it would be in our best interest to purchase a center instead, so again, like last week, we're stuck until we get that part.
And that sucks. (I was really hyping myself to cut some grooves too!)
I decided to revisit my lightsaber CAD files and redesigned and rescaled nearly the entire thing. (Which is convenient because I've haven't posted those files here.)
And that sucks. (I was really hyping myself to cut some grooves too!)
I decided to revisit my lightsaber CAD files and redesigned and rescaled nearly the entire thing. (Which is convenient because I've haven't posted those files here.)
My previous hilt design was just a 1.5in OD (Outer Diameter) tube with some threads at the bottom. I changed the design so a 1.5in OD tube with a 1.25in ID (Inner Diameter) would fit right over the top serving as the blade guard. I made the numbers nice and round as well. The hilt is intended to look slim, with the pommel and the blade guard protruding a by quarter of an inch. (I want the extra space on the hilt so I can wrap it with leather or add a samurai braided grip.)
As for the pommel and blade guard; they both got upscales so that the numbers would be nice and round, and the pommel got a small 30 degree chamfer around the edge.
As for the pommel and blade guard; they both got upscales so that the numbers would be nice and round, and the pommel got a small 30 degree chamfer around the edge.
(WEDNESDAY 2/24/16)
The center isn't here yet, so Harrison and I found some other stuff to do. We sat in on another Nepris Conference, this time about the mobile industry and the mobile design world. This conference was actually planned, and had like, a presentation and everything. It was about an hour long, a bulk of the time was spent discussing security and millennials being "THE COOLEST GENERATION EVER WOAH!!!"
Nothing Michelle Obama hasn't already told us.
Other than that, I helped out with some menial soldering. Not too much to say today.
Nothing Michelle Obama hasn't already told us.
Other than that, I helped out with some menial soldering. Not too much to say today.
(Thursday 2/25/16)
Still, no center. Harrison and I spent yet another day helping out. Today we helped our tall friend Nathan with his project. He's making a mechanical clock out of wood, and the whole thing is super cool and stuff.
I helped him make some wheels and gears. With that, I learned how to use three machines; the wheel sander, the jigsaw and the scroll saw. Here's a couple pictures of my primary handywork.
I helped him make some wheels and gears. With that, I learned how to use three machines; the wheel sander, the jigsaw and the scroll saw. Here's a couple pictures of my primary handywork.
UPDATE: The center actually got here fourth period, after Physics... Well, at least we get the lathe all day tomorrow!
(FRIDAY 2/26/16)
Today we finally made significant progress on the lightsaber!
Without further adieu, here at the pictures!
Without further adieu, here at the pictures!
As you can see, we have cut the blade guard lip on the tip (by the new, SPINNING center!) and we've also cut all six of the grooves, two large ones and four small ones. Cutting these grooves was no small task either, it was pretty scary to be honest! Every time we would make a pass and cut deeper (especially on the large grooves) the lathe would make this horrible screeching noise and would vibrate like it was experiencing a seizure. Scott stopped us on a noticeably horrid pass and taught us about resonant frequency.
Resonant frequency is the frequency at which something likes to vibrate. The horrible screeching noise was a result of the saber hilt matching the lathes resonant frequency during a pass. To counter this, we need to change the speed of the cutting tool, or the lathe's RPM. (Typically, when you hear that horrid noise, you want to crank faster.)
With the grooves out of the way, we need to power finish this, and the hilt will be done! (Minus the threads at the bottom.)
Resonant frequency is the frequency at which something likes to vibrate. The horrible screeching noise was a result of the saber hilt matching the lathes resonant frequency during a pass. To counter this, we need to change the speed of the cutting tool, or the lathe's RPM. (Typically, when you hear that horrid noise, you want to crank faster.)
With the grooves out of the way, we need to power finish this, and the hilt will be done! (Minus the threads at the bottom.)