The MP CNC (Mostly Printed CNC) is now working and being tested as a pen plotter before attaching a rotary tool. There have been some interesting problems. To find out more about those and my recommendations read on. Continue reading MPCNC Testing
As mentioned previously on this blog, this is a motard style conversion of a Honda CRM 250 using a 2007 model Aprilia RS-125 wheels, discs and front brake caliper.
A custom bracket was designed in Solidworks to adapt the radially mounted caliper to the original brake caliper mounting holes. Designing in 3D allowed the part to be simulated (FEA) with heavy braking loads and calculate the factor of safety, stress, strain and distortion.
One of the advantages of using the Aprilia wheels over the popular wire spoke wheels is that they incorporate a cush-drive to reduce driveline vibrations. Continue reading Motard Complete & Tested
It has been very busy here with numerous projects but the main project has been a new simple CNC router.
This is based on the “Mostly Printed CNC” machine that has featured on Hackaday, Thingiverse and other websites. This is small 3-axis machine with belt drives on the x & y axis. The z-axis has been upgraded to a lead-screw and nut.
The purpose of this machine is to get familiar with the software & hardware before commencing work on a larger platform router and then on to a third machine which should be a solid steel frame for machining metal parts. Continue reading Workshop Projects
I wanted to make an improvement to the quadcopter since the timber arms, although cheap to replace, tend to break too easily. The main problem is that on impact the force tends to split the timber where it mounts into the hub.
I came up with a quick printed arm design and then did some testing. This also gave me a chance to compare the real life results with the FEA simulation. Here are the results. Continue reading FEA Simulation & Real Life Testing
Recently turned a few spacers on the lathe for the CRM to motard conversion (see earlier posts – CRM 250 with Aprilia RS-125 wheels & brakes).
The toroidal pick-off from the previous post has been printed. Continue reading Toroidal Pick-Off Printed
What is a toroidal pick-off?
This was a recent project to create a toroidal (doughnut) shape to surround a pelletron-chain in a high voltage machine with an applied potential. The cut-away section is to allow the chain to come out without damaging the part if it were to break while running.
Following on from the earlier post I have carried out further refinement with FEA of the Motard brake bracket.
The first design was somewhat simplified to provide mounting of the Aprilia brake caliper to the CRM 250 without too complex a shape so that it could be produced using a manually operated mill and some hand tools to fabricate. Looking at the results from the simulation showed one area that required improvement, between the upper caliper mounting bolt and the upper bracket bolt. As the following image shows.
Sorry for the lack of updates as I was overseas for a few weeks.
Now to the article, FEA or Finite Element Analysis is an excellent tool for verifying and improving your design. The following image is of a model I have created of the Honda CRM250 front fork with the custom designed adapter bracket and radially mounted caliper from an Aprilia RS-125. Continue reading FEA of Motard Brake Bracket