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Real Robotics Discussion / Basic Things To Know
« on: June 15, 2010, 03:43:44 AM »
i though i would make this thread because i find that the problem here is not a lack of ambition or creativity, but a lack of knowledge. so I'm going to start by post helpful videos and links on basic things that you need to know to build a basic combat robot
lets start with Soldering
when i first started soldering i didn't know how to do it properly, i always tried to over tin the tip then join the two joints with the excess on the tip. this of course never worked, and ill explain why, when soldering the solder is drawn to where the heat is and sense the heat at the tip of the iron it was drawn to the tip, not the wire. so in order to solder properly you want to tin the tip (coat it thinly with solder), wipe off the excess on a damp sponge, then use the tip to heat the joint, and when the joint is hot enough apply you solder till evenly coated.
see video for fully demonstration
How to Do It: Basic Soldering
notes:
Make sure you use rosin core solder, if you use the wrong kind of solder (acid core, meant for plumbing) because if you do your joints corrode within a short time of soldering them
Cutting Plastics
I generally use a table saw and a cut off saw with a fine tooth blade for all my right angle cuts. And i use a saber saw for angled, or curved cuts, and i have sometimes used my milling machine with an 1/8 end mill to do fine cuts and rounded cuts with my rotary table. the this to remember when making cuts is to follow all the standard rules of the machine you are using
anyway here's a pretty good overview, although you will never use the first method because you will never use acrylic in a combat robot, and you can ignore the end because the point is the tutorial is to demonstrate how to do it yourself rather then to pay for someone else to do it for you
Drilling and Tapping both Plastics and Metals
when using a drill press the key thing to remember is the slower the better, especially with larger drill bits and harder metals. No matter what your drilling you want to make sure your piece is securely clamped or bolted down, NEVER try and hold the piece your drilling if the bit catches and spins the piece it will hit your hand several times before you could even think about moving out of the way. when drilling a hole you want to make 1/16" to 1/4" deep pushes depending on the material then back out clearing the chips and debris, don't try to force the bit, just apply moderate pressure and let the bit cut at its own speed, this is important when drilling plastic because if you push to hard or fast you will simply melt the plastic, it is also important when drilling metals because if you force the bit to hard or to fast is will simply dull or break.
when tapping first make sure your hole is the appropriate size (see drilling and tapping chart:http://www.shender4.com/thread_chart.htm) then apply an appropriate amount of tapping fluid then begin the tap, gently push the tap into the hole and slowly turn the tap till it begins to catch, then continue driving the tap in, turning the tap about 1/2 turn out every full turn in. this breaks of the burs and clears chips. never try to force the tap for you may break it and always make sure the tap is directly in line with the hole or it will simply create warped threads
Cutting Metals
how you cut metal all depends on the type of metal your cutting, aluminum should never be cut with a standard metal cut off saw or gridded because the aluminum will build up on the wheel, make it off balance, and eventually blow apart causing serious injury or even death to the operator. the best method for cutting aluminum would be to use a band saw with the proper teeth per inch, a sawzall saw also with the proper teeth per inch, or even just a standard hacksaw. when using a band saw make sure the the guards are properly adjusted, and when using a sawzall or hacksaw make sure you piece is secured properly. A hacksaw is a standard hand tool that is easy to use but can still be dangerous if not used properly, in order to use a hacksaw properly you want to take long even strokes using the full length of the blade at a rate of about 40 strokes per minute so not to where out one spot an quicker then any other. when reaching the end of a cut you will notices an change in pitch at this time you will want to slow down so when you finish the piece off you won't cut your self on the burr. also always make sure both hands or holding the hacksaw this way you will never slip and cut yourself. you can cut steel all the same ways you cut aluminum as long as its hardness is not greater then the blade you are attempting to cut with. in edition you can also cut steel with a metal cut off saw
band saw
sawzaw
cut-off saw
i think thats about enough for now if you have any specific questions please post them here and i will discuss what i know, i have over 5 years machining experience and would be more then happy to share my knowledge on the subject so if there is something your not sure how to make just ask
and dont forget to always wear your safety glasses, you only have one set of eyes and i would hate yto see you lose them over something stupid like cutting a 5 dollar piece of metal
lets start with Soldering
when i first started soldering i didn't know how to do it properly, i always tried to over tin the tip then join the two joints with the excess on the tip. this of course never worked, and ill explain why, when soldering the solder is drawn to where the heat is and sense the heat at the tip of the iron it was drawn to the tip, not the wire. so in order to solder properly you want to tin the tip (coat it thinly with solder), wipe off the excess on a damp sponge, then use the tip to heat the joint, and when the joint is hot enough apply you solder till evenly coated.
see video for fully demonstration
How to Do It: Basic Soldering
notes:
Make sure you use rosin core solder, if you use the wrong kind of solder (acid core, meant for plumbing) because if you do your joints corrode within a short time of soldering them
Cutting Plastics
I generally use a table saw and a cut off saw with a fine tooth blade for all my right angle cuts. And i use a saber saw for angled, or curved cuts, and i have sometimes used my milling machine with an 1/8 end mill to do fine cuts and rounded cuts with my rotary table. the this to remember when making cuts is to follow all the standard rules of the machine you are using
anyway here's a pretty good overview, although you will never use the first method because you will never use acrylic in a combat robot, and you can ignore the end because the point is the tutorial is to demonstrate how to do it yourself rather then to pay for someone else to do it for you
Drilling and Tapping both Plastics and Metals
when using a drill press the key thing to remember is the slower the better, especially with larger drill bits and harder metals. No matter what your drilling you want to make sure your piece is securely clamped or bolted down, NEVER try and hold the piece your drilling if the bit catches and spins the piece it will hit your hand several times before you could even think about moving out of the way. when drilling a hole you want to make 1/16" to 1/4" deep pushes depending on the material then back out clearing the chips and debris, don't try to force the bit, just apply moderate pressure and let the bit cut at its own speed, this is important when drilling plastic because if you push to hard or fast you will simply melt the plastic, it is also important when drilling metals because if you force the bit to hard or to fast is will simply dull or break.
when tapping first make sure your hole is the appropriate size (see drilling and tapping chart:http://www.shender4.com/thread_chart.htm) then apply an appropriate amount of tapping fluid then begin the tap, gently push the tap into the hole and slowly turn the tap till it begins to catch, then continue driving the tap in, turning the tap about 1/2 turn out every full turn in. this breaks of the burs and clears chips. never try to force the tap for you may break it and always make sure the tap is directly in line with the hole or it will simply create warped threads
Cutting Metals
how you cut metal all depends on the type of metal your cutting, aluminum should never be cut with a standard metal cut off saw or gridded because the aluminum will build up on the wheel, make it off balance, and eventually blow apart causing serious injury or even death to the operator. the best method for cutting aluminum would be to use a band saw with the proper teeth per inch, a sawzall saw also with the proper teeth per inch, or even just a standard hacksaw. when using a band saw make sure the the guards are properly adjusted, and when using a sawzall or hacksaw make sure you piece is secured properly. A hacksaw is a standard hand tool that is easy to use but can still be dangerous if not used properly, in order to use a hacksaw properly you want to take long even strokes using the full length of the blade at a rate of about 40 strokes per minute so not to where out one spot an quicker then any other. when reaching the end of a cut you will notices an change in pitch at this time you will want to slow down so when you finish the piece off you won't cut your self on the burr. also always make sure both hands or holding the hacksaw this way you will never slip and cut yourself. you can cut steel all the same ways you cut aluminum as long as its hardness is not greater then the blade you are attempting to cut with. in edition you can also cut steel with a metal cut off saw
band saw
sawzaw
cut-off saw
i think thats about enough for now if you have any specific questions please post them here and i will discuss what i know, i have over 5 years machining experience and would be more then happy to share my knowledge on the subject so if there is something your not sure how to make just ask
and dont forget to always wear your safety glasses, you only have one set of eyes and i would hate yto see you lose them over something stupid like cutting a 5 dollar piece of metal