Thursday, 28 February 2008

Aborted attempt to make Rubber Rollers

I tried to make some rubber rollers for the Ball Mill yesterday.

In lieu if having any rubber pipe with an inside diameter of 8mm kicking about I tried molding rubber rollers using some Vinamold compound I had to hand and a piece of copper pipe.

All in all a dismal failure, the Vinamold as well as being Smelly/Smokey to work with when it is melted it is pretty viscose.

It couldn't flow down the copper pipe quickly enough as it cooled and the result was stuck all round the inside of the pipe and full of voids.

The roller core pulled out too easily as well (I had used a thin aluminum tube with OD of 8mm to fit the bearings and an ID of 6mm to fasten the roller to the bearings using M6 Studding and Nyloc Nuts.

Having tried this as an experiment, I think it could be successful if a two part mold was used instead of a tube. The mold is better made out of something that is a poorer conductor of heat too, so that the Vinamold doesn't set too quick.

I think I need to return to plan A and find some rubber pipe/hose that suits the job, for now.

Making a two part mold I think is a task for the milling machine when it is complete.

Don't Ball Mill in a Glass Vessel.

Progress is slow here at the moment.

Quick tip don't try ball milling in a glass vessel no matter how robust it feels, the glass will give. Even when done gently by hand.

I tried this to get the Anhydrous MgSO4 out of the Duran Bottle I had dried it in. Unfortunately it had caked around the sides.

Net result was that the bottle slowly went crazy paving. Upside though was I did get the lumps out of the bottle and transfered to another container one way or another, just wasted the bottle.

Wednesday, 27 February 2008

Orders mostly arrived

OK The steel has arrived, it took a while to hacksaw into halves for storage but is now done.

Have got a 34mm hole saw and the Ball bearings have arrived, hopefully we'll have some more progress soon and some more piccys to put up.

Monday, 25 February 2008

Ordered up Steel for next part of construction

Ordered up some 30mm x 30mm x 3mm square tube and the same in equal angle.

The square is to make the rails for the axes, I just need to locate a 34mm bi-metal hole saw now to fish mouth the ends of the square tube to fit the round profile of the frame tubes.

The angle will be used with the bearing units already constructed to make the carriages or running bits for the axes.

I think I will be drilling the frame pipes and putting M8 threaded stud through to clamp the rails in place. I have discounted welding as the frame is galvanized.

Now the drill is fixed I can do these things.

Thursday, 21 February 2008

Finished Anhydrous Conversion

Finished off the oven work for converting the MgSO4.7H20 to MgSO4, or at least I think I did. My kitchen scales are so vague I could be slightly out.

Best that I can tell it all worked though.

Also went to the supplier to get some Steel Ball Bearings to pulverise the MgSO4 into fine powder but they were out of stock. Ordered them anyway and will await their arrival.

Next task in the interim is to figure out how to make myself a Ball Mill. As I have no useful motors lying around I think I will try and sneak some time in, using the Food mixer's Power take off to drive the Mill.

Just need to make the rest of the Mill now.

Pillar Drill Fixed

The pillar drill is now fixed and operational again.

Yipee, basic machine tool now back on line. It is amazing just how much you take certain simple things for granted until they are no longer there.

So much frustration is caused by those moments when you think I could just do this , then that then the other...... ah I couldn't do just this because I have no pillar drill.


Wednesday, 20 February 2008

Started search to find a support paste

Started initial experimentation to find a salt based support paste for use in the second head of the Ianus Rapid Prototyping Machine.

First up is an attempt to use Epsom Salts (Magnesium Sulphate, MgSO4) starting with reducing the commonly available form into a fine ground anhydrous version.

Baking in the oven at 210 Deg Centigrade seems to be working but had to halt the experiment so we could make the evening meal in th oven. Will resume tomorrow.

Parts Arrived To Fix Pillar Drill

The parts arrived today to fix the pillar drill, so we had a session in the workshop and stripped the broken pieces from the drill. Ready to refit the new pieces tomorrow.

They must have had problems with the originals because the replacements have thicker castings and a metal crank instead of the plastic one.

Tuesday, 19 February 2008

Blagged the use of a Lathe

I have blagged the use of a Lathe from a good friend but need to repair it first, this is going to come in useful for those, if only I could turn this down/out by an x jobs. But I will need to organize myself to work on this as it is a 40Min 33Mile journey away. I guess this means no nipping back to try the part on Ianus

Monday, 18 February 2008

Pillar Drill Fixing Underway

Ordered the spare parts I wanted for my pillar drill over the weekend, hopping from foot to foot now waiting for them.

The table support casting had shattered where it tightens around the post one cold morning (Must be heat and cold combined with a weak casting).

The table had come crashing down the post and bent the carriage and trashed a couple of other essential bits on the way down.

Thursday, 14 February 2008

Ianus Bearing Mounts

Now I can start on work towards the slides etc for Ianus, here is the assembled bearing mounts ready to mount on trolleys. The idea for these came from clever but simple, the best ideas always are. We are using Skate bearings (608 ABEC 7) here, M8 x 20mm Machine Screws and M8 Nuts. These screw right into drilled and tapped holes on the trolleys.

Ianus Frame Assembly.

Ianus frame assembled and screwed down to base board gantry not tightened up to base frame yet as it needs positioning etc.

Ianus Initial Assembly

Ianus initial assembly, Note working lunch on table.

Ianus is born

Ianus is born (well the prototype test bed is at least)

Ianus is a dual head Cartesian with Independent Z axes on a common X and common Y platform.

The Y axis is the worktable which is full width and slides backwards and forwards on the bed frame.

The X axis is mounted to the head of the gantry and slides full width.

The independent Z axes are mounted to the X axis on the gantry one per side initially, though this could be modified to present more independent Z axes ie 4.

The tubes and fittings I wanted have arrived and I have assembled them to trial the ideas. I bought the pipe and clamps from they are located in Normanton, West Yorkshire, UK