Design for manufacture | Term 1 | Introduction into the workshop world

UCL | DESIGN FOR MANUFACTURE INTRODUCTORY WORKSHOP

P O R T F O L I O

KEERTHANA VIJAYAN | 19172401

CONTENTS

Joints Cube Tetra-helix

04 10 14

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Bucket Wheel

22 30

Scaffolding

42

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This was the first workshop and it helped get an idea of basic woodworking as well as the tools and machines I would be working with. The aim of this workshop was to create different types of wooden joinery.

I worked on 2 different types of joints. Both were joints that connected 3 members.

P R O J E C T

1

WOODEN JOINERY W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

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JOINT 1 Member 1- First stage

J

Final 3 members

oint 1 is a very sturdy joint with 2 different cuts. The 1st and 2nd members were mirrored replicas of each other and created the positives and negatives which the 3rd member then anchors in place. The cuts were straight ones and this gave me the opportunity to use the band saw. The 3rd member needed additional chiseling too.

Member 1 and 2 Member 1- Final stage

Assembly

Joint bottom view showing the detail

Member 3- Cuts made using bandsaw

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Joint 2 is a cleaner, more complex one with many partial, angular cuts which meant that the machinery wasn't of much help in achieving the form. The chisel became my best friend during the process of creating this joint. Chiselling in the intermediate areas was a very delicate process as we were working on soft wood which when chiselled wrong would have lead to self destruction.

The details mattered a lot and a little sanding of the tips of these parts made a huge difference to the integrity of the joint.

JOINT 2 Member 1- Final stage

The process started with the drawing and shading of the regions

to be cutout. Chiselling was then done upto a1 mm tolerance which was later sanded off to perfection.

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P R O J E C T

CUBE

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2

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The main thing learnt from this assignment was the process of de-

signing members for mass production. We used Joint 1 for the entire cube as each joint of the cube required 3 members. The machine was set to the desired distance and all the horizontal pieces were cut first, the distance was then altered and the vertical members were cut. The clean look of the finished product was the result of a good amount of sanding.

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Our introduction to computation. A digital

model of the tetra helix was first developed in Rhino. Different structural models were created and analysed. Finally the tetrahelix was chosen. The final structure comprised of multiple identical symmetrical modules.

P R O J E C T

3

TETRAHELIX W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

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JIG 1- FOR THE ANGULAR CUT Introduction to the world of Jigs!!

Cut -flip - cut

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JIG 2- FOR THE TAPER Bandsaw Piece to be cut

Cut -flip - cut

Jig Jig Base

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Based on the computer aided model a negative tem-

plate was generated to make the angular cut.

A horizontal piece is fixed to the end to hold on to while cutting. Safety first!!

An additional member was fixed on the template to secure the position of the piece to be cut.

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The Cooper Bucket works on the principle of contraction and expansion of wood. No glue is used.

All the wooden slats are held together by the metal rings.

The bucket consists of 4 main parts - Wooden Side Slats - Wooden Base - Metal Rings - Composite Handle

P R O J E C T

4

COOPER BUCKET W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

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The wooden side slats

were made trapezoidal so it formed a circle when arranged vertically. The angle was derived from the Rhino model. However a 1degree error during machine cutting made a huge difference in the end. A few pieces had to be taken off. A groove made at the bottom of all the slats housed the base.

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For the base, 5 wooden slats were glued

together, and then cut into the desired size using a template. A taper was then given to the edges to ensure that its well secured in the groove made in the side slats.

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METAL RINGS Planing has to be done to remove the ribs of the slats.

Each ring had to be carefully measured as the bucket is To do a good job planing, we’ve got to lock ourselves into a comfortable position.

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tapered. A perfect metal circle requires lot of hammering in the correct places. Once the desired size of the circle is obtained, the edges were welded together.

Starting from the largest, each ring had to be hammered down until its firmly in place.

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HANDLE AND WATER PROOFING

Linseed paste is applied along the edges of the base for waterproofing.

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Fel lo e s Sp okes

PROJECT 5

W H E E L

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Hob

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FELLOES

From the digital model created a template was

prepared using which the felloes were cut. The joing angle had to be precise to form a perfect circle.

Hence a jig was designed to sand it to the exact required angle.

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One of the felloes must be kept longer to account for the tolerance in the end.

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Tennons had to be cut in each spoke. This was done using a tennon cutter and another jig which held the spoke upright in a fixed position. There was a taper towards the end that had to be removed. I experimented with both the mechanical method and the manual method to do it. The manual method was most succesfull as I was already adept with the chisel.

The sharp edges were sanded off for the smooth, rounded look.

SPOKES/ TENNONS W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

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Rectangular slots were then cut on the

Three planks of wood were glued and then cut into a rough cylinder using a band saw to ensure smoothness when put on the lathe. A template was created for the shape of the hub. The main divisions were then marked to make sure the wood is not reduced from the wrong area.

HUB W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

hub to insert the spokes. The slots were cut in a staggered pattern to make sure the load is distributed equally when the wheel is used.

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he metal rim should first be heated to 250 degree C, so that it expands, and then hammered down the hub. The outer diameter of the metal rim for the hub has to be the same or just slightly lesser than the diameter needed. The hub has to be made wet before putting the hot rim in to prevent it from burning. Once the rim cools down it contracts, becoming tighter and inseperable.

HUB BAND W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

BOXING METAL INSERT W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

The felloes were joined to one another using wedges. To fix the wedges, slots were made in the center on

both ends of the fellows using a table saw. Slits were also made in the tennons to place wedges in, to tighten the grip between the felloes and spokes.

WEDGES W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

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CONCEPT

BALANCE

P R O J E C T

HUMAN INTERACTION

POINT OF CONTACT

6

SCAFFOLDING AND SURFACE W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

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2D EXTRUTION The form was made by multiple

singly curved members.This was achieved by placing each member in a separate plane.

Balance was the primary underly-

Based on this form, a prototype was made using laser cut cardboard. Joinery details and other analyses were done based on this prototype.

ing concept and using a curved base reduced its contact with the ground.

This in turn reduced the impact on the surface level.

From the prototypes we learnt that a narrow curve was stable only with a weight in the center whereas a wider curve was stable on its own.

FORM EVOLUTION | 3D W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

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Oak was chosen as its one of the best woods for

steam bending and it has more bending momentum after steam bending, an important requirement in this specific design.

The grains had to be parallel. The timber was soaked in water for a before steaming.

Air dried timber is the best for a day steam bending as Kiln dried timber doesnt absorb moisture. It still dried too quickly causing cracks in the timber when creating certain narrow bends.

MATERIAL SELECTION W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

Logs soaked for a day dried in few minute when kept out

Timber was soaked using a rain gutter- weights were placed on top to keep the wood from floating. a Aluminium channel was kept in between the weight and the wood to prevent staining.

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STEAM BENDING Jigs were developed for each member namely the belly, the shoulder and

the center pieces. The curves were made steeper after calculating the spring back. The center piece had positive and negative moulds, the belly had only the inner mould and the shoulder had a 2 part inner mould to optimise the material being used.

The metal strips helped in bending the plank. For the belly and shoulder, bending crochets were used for additional help. The metal strips were then built accordingly. The metal strips are taped to prevent rust from staining the wood.

BELLY-SHOULDERS- CENTER PIECE JIGS W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

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FINAL PARTS W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

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JOINERY DETAILS The belly and shoulder pieces were joined to the centerpiece using a rectangular metal ring. The location of the ring was anchored using wedges.

The centerpieces were then glued together.

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Each side has 4 metal rings joining 2 members with a metal strip inbetween holding everthing together.

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SURFACE

The surface was made up of thin wooden strips

which were connected using strings. These strings were connected to the shoulder through a metal joinery member.

The joinery member, made up of 2 metal plates was clamped on the the shoulder using 2 screws on either side. The upper member was thicker and had a 2mm hole through which the string was fastened.

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The surface straingtens itself and becomes functional only when people sit on either side.

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SADDLE & COUNTER WEIGHT W O R K S H O P I N T R O D U C T O R Y P O R T F O L I O S E P - N O V 2 0 1 9 | K E E R T H A N A V I J A YA N | 1 9 1 7 2 4 0 1

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CURTAINS ON THE FALL TERM

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