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Tool Knowledge

Summary :

I have extensive experience with mechanical fabrication, machining, and material testing, utilizing tools such as CNC and manual mills, lathes, MIG/TIG welding, and 3D printing for precision manufacturing. My proficiency extends to electronic prototyping, including soldering, breadboarding, and circuit assembly, as well as FEA and CAD software for structural analysis and design, as seen in my Projects section.

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Additionally, I have hands-on experience with casting, material testing, and measurement instruments, ensuring quality control and performance optimization in engineering applications.

Material Testing

This experiment involved identifying unknown metal specimens using uniaxial tensile testing with an Instron 3369.

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  1. Preparation:

    • Measured specimen dimensions and marked reference points.

  2. Testing:

    • Applied controlled tensile force, recording stress-strain data until failure

  3. Analysis:

    • Extracted yield strength, tensile strength, and elastic modulus from test data.

  4. Identification:

    • Compared results to known materials, matching steel to 1020 Cold Drawn Steel and aluminum to 6061-T6 Alloy with minimal error

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Key Skills: Material characterization, stress-strain analysis, mechanical property evaluation.

Machining & Manufaturing

This truck ornament showcases several manufacturing operations, highlighting their capabilities and limitations. The following tasks were carried out to manufacture the truck using green sand casting and aluminum metal:

 

1. Material Preparation

  • Melting Scrap Aluminum: Recycled aluminum scrap was melted in an induction crucible

 

2. Casting Process

  • Moisture & Sand Testing: Conducted moisture content analysis and compactability tests to ensure optimal mold consistency.

  • Mold Assembly: Assembled the two-part green sand mold, incorporating proper venting to allow gas escape.

  • Metal Pouring: Melted and poured molten aluminum.

 

3. Post-Casting Operations

  • Mold Breakout: Removed the solidified truck casting from the green sand mold.

  • Surface Cleaning: Used wire brushing to eliminate residual sand and oxidation.

  • Quality Inspection: Examined the casting for defects such as porosity, inclusions, or shrinkage cavities.

 

4. Machining & Finishing

  • Milling & Drilling: Machined critical features on the truck body for precision and assembly requirements.

  • Lathe Operation: Turned the wheels from stock material to meet dimensional specifications.

  • Drilling & Tapping: Drilled and tapped holes in the truck body and wheels for secure assembly.

  • Sheet Metal Bending: Bent sheet metal to form the truck bed.

  • Resistance Spot Welding: Welded the truck bed components using spot welding for structural integrity.​

  • printables_400x400_edited
  • GitHub
  • LinkedIn
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