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Working with the Workshop Andy Edgar

Working with the Workshop Andy Edgar . If you can buy it from a catalogue, buy it, don ’ t build it. US $400. Strategies. Don ’ t be lazy – design it yourself –that way you get what you want, or at least asked for. But get the WS to check a sketch first for manufacturability.

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Working with the Workshop Andy Edgar

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  1. Working with the WorkshopAndy Edgar

  2. If you can buy it from a catalogue, buy it, don’t build it. US $400

  3. Strategies • Don’t be lazy – design it yourself –that way you get what you want, or at least asked for. • But get the WS to check a sketch first for manufacturability. • Get as much right as possible first time, but allow for mods.

  4. Find 10 things wrong with this job request • No date • No charge code • Who is Dave? Contact details (room, phone #) • No idea of urgency • Material not specified • Thickness not specified • Quantity not specified • Depth of 5 x 5mm recess not specified • They can’t easily make a 4.37mm hole • They can’t make a square recess with a milling machine

  5. The lathe - turning

  6. What can be done on a lathe Routine Tolerance 0.1mm

  7. Making Holes/Threads Drills – only fixed sizes –typ. 0.5 mm increments Tolerance - ~ 0.1mm

  8. The Vertical Mill For making flat surfaces Tolerance ~ 0.1mm CNC – Numerically controlled

  9. Sheet metal working

  10. For a 6mm screw, the 6 mm means • The distance between consecutive turns • The diameter of the head • The maximum diameter of the threaded part • The minimum diameter of the threaded part

  11. Screws and Bolts • Which of the following heads are described as, • Phillips • Knurled • Countersunk • Allen/Cap • Hex • Cheese • Posidrive

  12. Materials • Common W/S materials are • Aluminium • Brass • Copper • Stainless steel (magnetic?) • Machineable plastic (acetyl) • (Polyethylene). Soft • Nylon ( bearings, gears) • PTFE (Teflon) • Perspex, Lucite, Plexiglas (PMMA). Hard, clear.

  13. “Exotic” Materials • Beryllium copper, phosphor bronze (springs) • Monel 500 (Cu-Ni, low therm cond. , non–magnetic) • Macor (machineable ceramic) • Viton (elastomer, high temp O-rings) • Kapton (polyimide, vacuum, insulation)

  14. Optical Windows – Glass & Acrylic

  15. Optical Windows - Silica

  16. Broad Spectral Range Windows

  17. UV windows

  18. IR Optical Window Materials

  19. Which Material? • Which of these W/S metals are not “pure ( >99%) metals? • Brass, copper, aluminium • Which of the W/S materials would you use for, • A cryostat for liquid nitrogen/helium? • A sample holder for cryogenics • A good electrical insulator for T<200˚C • An electrode holder for high temperatures? • Which metal would you not use for vacuum? • Which metal is the most expensive?

  20. Joining Materials

  21. Soldering and Brazing • Soldering (200-300˚C) • Brass, copper • Sn-Pb (banned) • Tin-Antimony • Have to remove surface oxide first with flux • Brazing (600-800˚C) • Brass, copper, steel, SS • Brass brazing rod, or • Ag-Cu-Sn “silver solder” • Hydrogen acts to clean surfaces

  22. Welding • Mainly steel, any other metal incl. Al • Filler of same metal used to reinforce joint • Localised electric arc melting of metal and filler. • TIG – tungsten/inert gas (argon)

  23. Glues • Aim for thin joints, clean surfaces first • Standard 2-part resin (araldite). Soften in acetone, flame. • Silicone RTV • Thermosetting polymers and resins ( hot glue) • Superglue (cyanoacrylate) • Soluble ceramics for furnaces • Low vapour pressure resin (Varian) • Silver-filled epoxy, silver conductive paint

  24. Two Examples of Clever Design

  25. “Kinematic” Bearings

  26. Translation Platform

  27. Drawings • Hand drawings are fine • Ruler is good for straight lines! • Use grid/graph paper • To scale is best • Sketch, front, top, side views for clarity (conventions) • Specify ID, OD, threads, material • If frequent user, consider CAD ( eg SolidWorks)

  28. Acknowledgements • Many diagrams and info from, “Building Scientific Apparatus” JH Moore, CC Davis, MA Coplan, SC Greer (new copy ( 4th edition) ordered for library)

  29. Table of Contents 1. Mechanical design and fabrication 2. Working with glass 3. Vacuum technology 4. Optical systems 5. Charged-particle optics 6. Electronics 7. Detectors 8. Measurement and control of temperature Index.

  30. 3d Printing - Justin

  31. 3D Printing • For personalised, custom-made lab equipment. • Requires a 3D design- solidworks • 3D printer- School of Architecture and Design.

  32. Solidworks • A 3D Computer Aided Design (CAD) software used to create a model. • The design starts with a 2D sketch and is extruded to give a 3D object. • The final design is sent as a .stl file to the printer. • The design is printed by slicing the design into 2D digital cross sections and depositing the materials layer-by-layer. • Materials used include thermoplastics eg. acrylonitrile butadiene styrene, polycarbonate, polylactic acid.

  33. IR Optical Window Materials

  34. IR Optical Window Materials

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