Assignment 1 Tray

Assignment 1 Tray




Main Aim: To create an aluminum skin to adhere to the contours of a tray.





Materials:  4 Rectangular shape wood planks
               
                    2 Flat aluminum sheet

Step 1: It is supposed to cut every side of big flat aluminum sheet to a proper size. Every side of aluminum should be 2 centimeters greater than corresponding side of wood plank.






Step 2: As can be shown in image 1, it is supposed to decide a proper size of the circle to make every corner of the tray. After deciding the circle size, we draw the contour of circle as can be shown in image 2. This means that the area which is out of the range of  the circle should be cut off.

Image 1

Image 2

Step 3: By using the machine which can be shown in image 3 and 4, the out-range area as mentioned in step 2 can be"cut off". This machine will rotate itself in very fast speed so that the surface of the plank where gets touch with the machine can be "cut off". Image 5 shows the result of the work.

Image 4

Image 3

Image 5

Image 6

Step 4 : Put the aluminum sheet between 2 wood planks, make sure that the wood plank is put at the center of the flat sheet. Clamp these 3 components in between the two templates. This ensures that the main base of the tray will not be distorted and will retain a clean finish.

Image 7

Image 8

Image 9

Image 10

Step 5: As it can be shown in the image 7,8 and 9, use white mallet to hit the edge of the aluminum to make a right angle. Note that when the surface of aluminum is very close to the wood plank, change white mallet to red one as shown in image 10. In this way, the surface of aluminum can fit

the wood plank well. This method applies to all the sides of the aluminum sheet.

Step 6:  when shaping the corner of the tray, same method is applied in step 5. Make sure the aluminum sheet does not overlap and use tin scissor as shown in image 11 and 12 to cut off extra aluminum.

Image 11

Image 12

Step 7 :  Take wood plank out of the tray. Actually, this is a very hard progress. It is suggested to twist a screw into the wood plank and then pull this screw out with plank.

Image 13

Step 8: Sanding and Polishing!

Finally!!!

Assignment 1 Blister

Assignment 1 Blister






Main Aim: To create an aluminum skin to adhere to the contours of a blister, of which focus is on sharp clean edges, depth of shape and smoothness of shape.





Materials:

Screw and nut

Aluminum sheet 200Mx200M

Wood mould 

Step 1: Use the machine shown in the image 2 to cut away the blister shape as can be shown in image 1. Make sure the edge of the blister is smoothed in this step.

Image 1

Image2

Step 2: Put aluminum sheet in between wood mould and use screws and nuts to fix them.

Image 3

Step 3: Use mallet in image 5 to change the flat aluminum to blister shape. Wooden mallet is supposed to be used in this step because the aluminum is very fragile, we need to be careful when doing this step.









For the edge of the blister, it is supposed to have a wood bar aiming at the curve of the blister and then use mallet to hit the wooden bar. This helps with dealing with the edge of the blister because the wooden mallet is too big to dive in.

Image 4

Image 5

Step 4: Sanding and Polishing!!!

Finally!!!!!!

Assignment 1 Torus

Assignment 1 Torus






Step 1: Drawing down several vertical lines as shown below, these lines are drawn to prevent malformation when hammering.

Step 2: Use the timber mould as shown below to bend the aluminum strip round. Make sure that the vertical lines are parallel to the vertical concave shape.

Step 3:  Use the mallet to make the aluminum strip fit the concave surface of the wooden mould. In this step, the aluminum strip will become straighter compared with before. Thus, it is supposed to bend it while hammering.

                             

Step 4: As shown below, it is supposed to move the bended aluminum while hammering it so that the concave surface can be shaped starting from the top of the strip to the bottom of the strip. Make sure the bended strip is moved vertically not horizontally so that the strip will be regular shape not abnormal.

Step 5: The metal horse shoe as shown in image H is used to make the edge of the torus. The red mallet in image K is used to hit the aluminum strip because the flat surface of the red mallet can make the edge perfectly fit the metal horse shoe. Note that it is supposed to make the edge by mallet
 starting from the inner space of the torus to the outer side to make a regular shape.

image H

Image J 

Image K

Step 6: Sanding then polishing!!!!

Finally!!!!!!!!