Mechanical Engineering
My interest in engineering became apparent when I started modifying 4WDs improving their capabilities, problem solving flaws in designs and coming up with new ideas to remedy them. Modifying suspension components to gain better handling for offroad racing, etc. As time moved on so did the complexity of the modifications to the point where I started designing parts in CAD and getting them machined.
In early 2010 I started a Pre-Voc Engineering Cert at TAFE where I have learnt to use lathes, mills, arc/MIG/oxy sets, sheet metal folders, band saws, guillotines, precise measuring and marking out tools, etc.
Examples of my work follow:
The soft face hammer they get you to make at TAFE as part of using the Lathes. This gave me experience in machining to a finish, knurling, offset tailstock machining. It also gave me a chance to machine different kinds of metals including copper, aluminium, brass, nylon and of course mild steel. I used both HSS and Tungsten tools. I finished the hammer first in the class and was given some brass to machine another head for the hammer as extra experience in machining different metals. All dimensions are within spec as to the plans we were all given.
To add a personal touch I ground a flat into the knurl and stamped my initials in the handle.
On the milling machines the project was to mill two parallel strips. Milled with excess material for later surface grinding. Slotted and drilled to reduce weight. The surface finish after grinding isn't as good as I wanted due to the grinders wheel being worn out and a lack of a spanner to change it at TAFE.
As an extra project for me to work on while the others in the class finish their hammers I was to make a screw jack. Consisting of three piece all which have a knurl and two with threads.
In welding I passed with ease using Stick Arc, MIG and Oxy. While getting to also do Oxy cutting, gouging and carbon arc gouging. This weld is of 5mm plate mild steel using 4mm electrode doing an outside corner weld.
Bronze brazing. Top of picture is of a fillet weld, middle is lap weld and the bottom is bevel butt brazed cast iron.
This is the hand tools project to learn the correct filing methods. Using 3mm brass bar I had to trace out from a template using the scribe. Then hacksaw off the excess material after which I filed down to the scribed line using a selection of Bastard, 2nd Cut and smooth files. I then drilled out the windows and filed to the line using smaller files. Once filed down I draw filed the edges, emery papered the surface then polished it smooth.
As the second project with hand tools they got me to file out a dummy gasket from mild steel plate. I had to mark it out from a drawing using a scribe, rule and compass. I chose to cut the middle out first to leave as much material on there while drilling out holes to get the hacksaw started. I then cut off the excess around the outside and filed the lot down to the witness marked scribe line.
For the last of the hand tools exercise I made a drill gauge. Able to measure millimeter sized drill bits from 2mm to 10mm it also has the 112 combined degree angle needed for sharpening drills correctly.
As a project of my own I used the lathe to turn down some tractor pins for the use of swing arm pins in a 4WD rear tyre carrier. I used a left hand tool to cut the larger side with a 45 degree taper. I then turned the lot around in the lathe and turned down the 25mm diameter to 22mm and cut an M22x1.5 thread.