Project 3: The Tray

Project 3: The Tray 

Introduction

This is the third project for BEIL0014 for making 2 identical trays with the cooperation of two people. For this project me (Louis) and Iverson formed a team of 2. 

Procedure

We start with 2 plank of wood and 2 sheets of metal. First I have chosen a suitable radius for the corner of the tray which is 50mm. I then draw lines around the plank of wood with the circle tool disturbed in class. 

Next, I bring the plank of wood to the grinder to grind out the extras

Until the wood perfectly matches with the circle tool. 

In order to achieve a symmetric shaped tray, I measured the length of the plank and the sheet metal and draw markings on the sheet metal so that the plank of wood sit exactly in the middle of the metal. 

The marking are shown on the metal for both sides:

Next, again with the help of the circle tool, I was able to cut off the sharp edge of the metal and turn them into rounded corners. 

Then I place the metal in between two wood planks with the wood sit exactly in the marks I have created previously. I then place the whole thing in a large clamp which is directly attached to the working bench. The hammering process then begins. 

Metal fold is very common in the process of working on corners. The solution to avoid metal folding is to add a support underneath the corner while hammering. 

After the work has been nearly finished, it has been taken out from the mold to do some minor fix on the metal since the tray has been deformed a bit in the process of taking the wood out of the tray. 

Next, it is bring to coarse sand paper to grind the bottom and making the tray look even. And for the surface of the tray, different grades of sand paper has been applied from coarse to fine. This makes the finishing of the tray looks shiny. The process is being repeated for the second tray.

The finishing product is shown as below: