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Working with the Workshop
Andy Edgar
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If you can buy it from a catalogue, buy it, don’t build it.
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US $400
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Strategies
• Don’t be lazy – design it yourself –that way you get what you want, or at least asked for.
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• But get the WS to check a sketch first for manufacturability.
• Get as much right as possible first time, but allow for mods.
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Find 10 things wrong with this job request
1. No date
2. No charge code
3. Who is Dave? Contact details (room, phone #)
4. No idea of urgency
5. Material not specified
6. Thickness not specified
7. Quantity not specified
8. Depth of 5 x 5mm recess not specified
9. They can’t easily make a 4.37mm hole
10. They can’t make a square recess with a milling machine
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The lathe - turning
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What can be done on a lathe
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Routine Tolerance
0.1mm
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Making Holes/Threads
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Drills – only fixed sizes –typ. 0.5 mm incrementsTolerance - ~ 0.1mm
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The Vertical Mill
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For making flat surfaces
Tolerance ~ 0.1mm
CNC – Numerically controlled
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Sheet metal working
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For a 6mm screw, the 6 mm means
1. The distance between consecutive turns
2. The diameter of the head
3. The maximum diameter of the threaded part
4. The minimum diameter of the threaded part
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Screws and Bolts
• Which of the following heads are described as,– Phillips– Knurled– Countersunk– Allen/Cap– Hex– Cheese– Posidrive
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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.
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“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)
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Optical Windows – Glass & Acrylic
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Optical Windows - Silica
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Broad Spectral Range Windows
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UV windows
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IR Optical Window Materials
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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,
1.A cryostat for liquid nitrogen/helium?
2.A sample holder for cryogenics
3.A good electrical insulator for T<200˚C
4.An electrode holder for high temperatures?
• Which metal would you not use for vacuum?• Which metal is the most expensive?
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Joining Materials
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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
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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)
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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)
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• Superglue (cyanoacrylate)• Soluble ceramics for furnaces• Low vapour pressure resin (Varian)• Silver-filled epoxy, silver conductive
paint
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Two Examples of Clever Design
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“Kinematic” Bearings
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Translation Platform
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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
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Acknowledgements
• Many diagrams and info from,
“Building Scientific Apparatus”
JH Moore, CC Davis, MA Coplan, SC Greer
(new copy ( 4th edition) ordered for library)
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Table of Contents
1. Mechanical design and fabrication2. Working with glass3. Vacuum technology4. Optical systems5. Charged-particle optics6. Electronics7. Detectors8. Measurement and control of temperatureIndex.
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3d Printing - Justin
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3D Printing
• For personalised, custom-made lab equipment. • Requires a 3D design- solidworks• 3D printer- School of Architecture and Design.
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Solidworks
• 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.
• 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.
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IR Optical Window Materials
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IR Optical Window Materials
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