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Metal Chess Set Design
Team Checkmate Sadik Antwi-Boampong, Aaron Buchok, 3.042 Project John Rogosic, Tami Jean Shinkawa
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Presentation Outline
Initial ConceptDesign ConstraintsProposed Project
Design ProposalMethodsMaterials SelectionMaterials CharacterizationSurface Treatments
ConstructionPiecesBoard
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Initial Concept
Primary GoalCreate a functional chess set and gain basic experience with a wide variety of materials processing and analysis tools
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Chess Experts
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Design Constraints
World Chess Federation guidelines for chess equipment http://www.fide.com/official/handbook.asp?level=C02
The King`s height should be about 9.5 cm. The diameter of the King`sbase should measure 40 to 50% of its height.
The size of the other pieces should be proportionate to their height and form; other elements such as stability, aesthetic considerations etc., may also be taken into account.
The weight of the pieces should be suitable for comfortable moving and stability.
The dark pieces should be brown or black, or of other dark shades of these colours. The light pieces may be white or cream, or of other light colours. The natural colour of wood (walnut, maple, etc.) may also be used for this purpose. The pieces should be pleasing to the eye.
Boards should be rigid. The size of a square should be twice thediameter of a pawn’s base. It is recommended that a side of the square should measure 5 to 6.5 cm.
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Design Proposal
Cast metal chess piecesBoard assembled of individual tiles inlaid on a frame
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Design Drawing
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Construction Methods
3D Scanning3D PrintingMetal CastingCNC MachiningMetal Joining ProcessesPolishing/Surface TreatmentsInjection Molding
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Investment Casting
Wax model is prepared and encased in ceramic
Wax is melted out, and metal is poured into the cavity
Captures more detail than sand casting
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CNC Machining
Widespread industrial production technique
Variety of available tooling for all sorts of tasks
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Injection Molding
Molds designed for easy injection molding of pawn pieces
CNC machined from aluminum
Cast both pure plastic and colored pawns using dye pellets
Only pawns injection molded as the time commitment is significant
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Materials Selection
Fracture resistance
Dent resistance
“Comfortable” weight
Surface finishing options
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Materials Options
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Cu-Zn Phase Diagram
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Brass Composition
57.49 % copper38.82 % zinc
Trace amounts:Tin Lead Iron Nickel Aluminum Manganese Silicon
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As-Received Material
Both beta and alpha phases present in considerable amounts
Few voids in the material
100x magnification
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Cast Material
Far less alpha phase present in the cast sample
Many voids visible
100x magnification
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SEM Analysis
Conducted SEM on as received and cast samples
Compared results to manufacturer specifications
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Sample Spectrum
Peaks correspond to particular elements
Integration corresponds to number of signals
As received sample shown
Elements present as expected, within about 0.5% compositional difference
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Cast Sample Inclusions
Iron inclusions in “trigonal”arrangement
Less voids than expected, but still more than as received
Less alpha phase present than as received, but still present
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UNDER CONSTRUCTION
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Initial Development
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New Plan
Commercially produced chess pieces purchased and used as a template
Two part polyurethane material is mixed in a plastic container and placed under vacuum conditions to remove bubbles
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Investment Complications
Occasionally problems occurred with molds
Ceramic did not properly hardened, remained soft and wet for several daysCracks during heat treatmentEntrapped air bubbles
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Our First Pawn
Piece came out relatively smooth for a raw casting
Minor surface flawsAir bubbles filled with metalSmall holes in surface
Pieces were sawed off and the bottoms were ground flat
Surface imperfections were ground off
Final surface was polished for coloration
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Pawn Polishing
As-cast (left), sand-blasted (middle), and machine-polished (right) pawns are shown above. Note the difference in coloration.
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Patination
Forming an oxide layer on the surface of a metal
Commonly occurs as a result of weathering, and is a common tool used in artistic endeavorsCan affect color quite dramatically
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Electroplating
Ni-W electroplating process used
Xtalic corporationNano-structured surface coating created by plating Ni and W out of solution simultaneously using controlled proprietary conditions
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Board Construction
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Board Machining
Machined in multiple phases
Fine tip used to tighten corners
Individual tiles were water jetted, colored, lacquered, and fixed in the board cavity
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Injection Molding
Quick and easy “insert”components designed by Aaron
Injection molded pawns successfully, with minimal guidance and oversight
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Injection Molding
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Questions?