This section will detail the process of machining the delamination device
Figure 4: Cutting rollers
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The rollers came in a three foot bar and had to be cut to 12" bars. The bandsaw was set at a lower speed and feedrate due to the rollers being steel compared to aluminum.
Machining
Figure 1: Top
Figure 1 shows the cover for the top of the device. This was the first part completed.
Figure 2: CNC lathe
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This was used to bore out the holes for the cams. The entire process was completed with help from Ted Bramble
Figure 3: Machined cams
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There cams are fresh from the CNC Mill. The excess on the bottom was machined off in the lathe.
This section will detail the construction process. It will include drawing trees and various stages of construction of the assembly.
CONTRUCTION
Figure 5: Tapping 3/8"-16 hole
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There were numerous holes that needed to drilled and tapped. There were two 3/4"-10 holes that were substantially more difficult than the 3/8"-16 holes.
Figure 6: Milling shaft supports
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A late stage redesign called for supports for the shaft. This was due to the need for the shafts to be adjustable in the frame of the device The idea of using cubes with a hole bored in the middle was the simplest solution. The material ordered was slightly over-sized so it had to be milled down to size.
Figure 7: Drilling for 3/4"-10 tapped hole
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A series of increasingly sized drills is used to drill the hole for tapping
Video 1: CNC Milling of cams
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This video shows the operation of CNC milling the cams. The programming and running of the machine was provided by Ted Bramble.
Figure 8: Final assembly
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Figure 8 shows the completed delamination assembly minus the cover.
Summary of Construction Process
The construction of the bending device was a lesson in project management and the importance of optimizing the order of machining. There were many design changes made during machining and many mistakes made due to these design changes. An important lesson was utilizing the CNC machine to conduct multiple machining operations at one time instead of trying to do multiple operations and compounding errors.
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There are essentially two different construction operations with this project. The first was construction of the device. The second is the construction of the mounting base and electrical wiring of the motors. This second construction operation is arguably the largest bottleneck in this process as it prevents testing until it is completed.
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