This project had a lot of moving parts (literally and figuratively!). Although the design specification, task analysis, and timeline helped me organize myself, I didn't know exactly how everything would unfold until I actually worked through each step. Furthermore, I realized that I often underestimated the time it would take me to complete several of the tasks because I would run into problems I hadn't planned for or even thought of.
Before I could even hold something physical in my hands, I had to create my Aspire files. I could have printed out the plans and hand-cut the parts, but since I had the Fab Lab's CNC machine available to me, I decided to use that instead. First, I had learn how to use the software, and then I had to refresh myself on how to use the ShopBot. The plans didn't come with any instructions on which toolpaths to create, so I basically designed my own cutting files from scratch with the .dxf files of the parts. In addition to figuring out how to create toolpaths in Aspire, I was working with really small holes. Therefore, I had to be mindful of the size bit I was using because the hole needed at double the bit's diameter to allow the bit enough room to move. Along the way I had to modify my toolpaths several times as I worked through my files. For example, I had to go back and add tabs to all of my profile cuts because I didn't know that I needed them for all of my parts. Also, I learned that if I made my cut depth a little more than the thickness of the material, it would ensure a clean cut all the way through. Milling the parts came with its own set of issues and challenges. On one of my first cuts, I didn't tighten the collet enough around the bit, so when it started cutting, the bit slipped and made a terrible noise. Luckily, the bit was undamaged and no one was hurt. After I drilled down the 3/8'' HDPE which covered the whole table, I realized that there was no space to put the zero plate to zero the z-axis. The quick fix was to change the origin from the machine bed to the top of the material in the document settings of Aspire. Lastly, I had to keep in mind the parts that required "special treatment" post-process. For example, some parts had side hole that needed to be drilled and the escapement drum had a .03 in. slit on the side. As I became more familiar with all of the tools in the Fab Lab, I was able to figure out how to accomplish these tasks, such as using the band saw to cut the slit. Asking questions also relieved my frustration when I was stuck and didn't know how to proceed.
The most frustrating (and most stressful) part of this project by far was tapping the holes of my tubes. It was like watching paint dry, and there was nothing I could do to speed it up. If I tried to rush it, the tap would break and stop the hole of the tube. Unfortunately, this happened to me twice, and both times I had to restart and tap the other end of the tube. Just getting the tap to catch straight was a challenge (it took over an hour the first time!). Then, I spent three more hours threading the tubes. Not only is threading the tubes laborious and monotonous, but it also doesn't feel like you're getting anywhere until you reach the end. This step in the process definitely taught me to have patience, determination, and focus.
Doing such a machine-heavy project, I obtained experience working with powerful tools. Before starting this project, I had only used the laser cutter and the ShopBot maybe a handful of times. Now I think I have used almost all the tools in the Fab Lab including the drill press, cut off grinder, bandsaw, table saw, table sander, Dremel, and arbor press. First, Mr. Rudolph instructed me on proper safety techniques and gave me demos on how to use each one, but after that, I was on my own. It was scary at first because I knew these machines could hurt me if I wasn't careful, but I slowly gained confidence as I used them more and more. I learned that as long as you've taken all safety measures and can predict how the machine will behave, everything should be fine. Instead of approaching them with fear, I began to appreciate their power and efficiency. Nothing has made me feel more powerful than grinding through metal and seeing sparks fly. Furthermore, as I continued working with the tools, I began to be able to discern when things were going awry and adjust accordingly. Since I am planning on becoming an engineer, this exposure to hands-on fabrication was great preparation.
One of the best teachers throughout this project was making mistakes. Sometimes you have to go through the ugly in order to learn how to do it. For example, when threading my tubes, I had to break a few taps to understand the limit of the torque. The tradeoff of the hard material of which the tap was made was the brittleness of it. The long torque handle gave me a false sense of how much force I was using, and I ended up pushing the tap past its breaking parts. Afterwards, I used extra caution and aired on the side of being too safe. Furthermore, I had to figure out a lot on my own, but in the end, it gave me more confidence. I realized that I can problem solve well and use what I know to conquer any challenge. Most importantly, I learned that a project like this requires you to stay the course and not give up. Remaining determined even during the most frustrating parts is crucial to reaching the finish line. Coming into the Fab Lab in the morning and during my free periods at school served me well, for I have achieved a working prototype!
My working prototype has rings that spin, a functioning spring/winder, and fully assembled subassemblies. However, the ratchet teeth are not catching properly, which stops the motion of the rings. Mr. Rudolph suggested I re-mill the ratchet teeth and not sand them down because right now, the rod that is supposed to catch on them is missing them by a few millimeters. I think I need to investigate the ratchet teeth mechanism a little more before I can effectively fix the problem. For my finished product, I also need to add the spinner connect caps to the rings. They are not essential to the functionality of the Annulation, but they contribute to a completed look. I will also realign the assembly so that the spring wraps around the drum core better.
The second leg of this project was not as intense as the first in the sense of labor, but mentally, it required more determination and willpower. Even though I knew the end was near, it seemed like the last 10% took half of the total time it took to complete the project. In order to get the project done by the hard deadline (Feb. 8), I had to come in before/after school to work on it. Ultimately, that hard work paid off, and I was able to present something I was proud of. There's no better feeling than accomplishing a goal and finishing what you started.
Described in detail in my 2nd semester daily journal, I faced many challenges that I had to overcome. The biggest setback was the stuck bearing on the shaft. I feared that I would have to mill all my parts again and/or redo all the hard work I did first semester. Fortunately, Mr. Rudolph helped me immensely by building the bearing puller, which worked like a charm. The first lesson I learned from that experience was to stay calm and not freak out when you hit a road block. I was getting very frustrated and upset, but then I realized that neither the frustration nor the stress was making things better. What I needed to do was to take a step back and attack the problem one step at a time, asking for help when necessary. Subsequently, I learned that there are many ways to solve a problem and sometimes it takes more than one approach/method. Mr. Rudolph showed me how being adventurous and clever can lead you to creative solutions that end up resolving the issue. I realized that if you're too afraid of making a mistake, you miss out on so much. In the Fab Lab, the possibilities and resources are limitless. You just have to be bold enough to experiment with different ideas and go for it.