This is a small quick project I use in my after school Engineering club for Yr9 students (13year olds). As with all my instructables its achievable by all and results in a quality product that works well. It only takes 1-2 hours to make depending on ability of student, this makes it a real confidence builder.
This project was used as part of a enterprise activity where students made various products to sell on a market stall, this was to raise funds to finance an electric car they wanted to build.
By making an aluminium keyring KS4 GCSE students will learn and apply knowledge in a practical situation. This knowledge covers accurate use of the measurement dials on the X axis of a metal lathe, how to accurately drill to a given depth, chamfer and face off a component. This project was used as part of a enterprise activity where students made various products. By using this project in their enterprise activity students gain entrepreneurial skills and begin to see the link between time to make / materials cost Vs sale price.
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Step 1: Working Drawing
A working drawing is a 2D drawing that shows you the dimensions needed to make a product or component.
Step 2: Using the Lathe
- Put your work piece (Ø12mm aluminium rod) into the lathe chuck
- You should have approximately 50mm sticking out the chuck
- You must never leave the chuck key in the chuck as this is very dangerous
- Ensure the correct cutting tool is in position and that it is at the correct angle for facing off
Step 3: Centre Drill
• Centre drill the end
Step 4: Drilling
• Drill Ø4mm x 15mm deep
Step 5: Sanding
- Sand outer surface
- Be very careful not to touch the spinning chuck with your fingers
Step 6: Grooves
- Set the cutting tool to the correct angle
- Decide where the first groove will be
- Advance the tool forward to create the first cut, it should be approximately 2mm deep
- Bring the cutting tool back and rotate the X-Axis 4mm (two turns)
- Repeat the cutting process
- Create three grooves
Step 7: Parting Off
- Set the parting off tool to exactly 900
- Part off
Step 8: Chamfer
- Set the parting off tool to 450
- Create a chamfer on both ends
Step 9: Cutting Cable
- Decide how long you want the cable to be (mine was 80mm)
- Use wire cutters to cut cable
Step 10: Glue
- Mix a pea sized blob of epoxy resin and carefully put into the hole
- Fold the cable over and put the ends into the hole
Step 11: O-rings
- Roll on the o-rings
- Enjoy :)