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10.1.2 CUTTING
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To cut metal, use a hacksaw outfitted with a fine-tooth blade, one with 24 or 32 teeth per inch. Coping saws, keyhole saws, and other handsaws are generally engineered for cutting wood, and their blades aren t fine enough for metal work. You can use a power saw, like a table saw or reciprocating saw, but, again, make sure that you use the right blade. For large aluminum or steel angle stock, an abrasive cutter is invaluable and will make short work of any cuts remember that the cut ends will be hot for quite a while after the cutting process! You ll probably do most of your cutting by hand. You can help guarantee straight cuts by using an inexpensive miter box. You don t need anything fancy, but try to stay away from the wooden boxes. They wear out too fast. The hardened plastic and metal boxes are the best buys. Be sure to get a miter box that lets you cut at 45 degrees both vertically and horizontally. Firmly attach the miter box to your workbench using hardware or a large clamp.
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10.1.3 DRILLING
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Metal requires a slower drilling speed than wood, and you need a power drill that either runs at a low speed or lets you adjust the speed to match the work. Variable speed power drills are available for under $30 these days, and they re a good investment. Be sure to use only sharp drill bits. If your bits are dull, replace them or have them sharpened. Quite often, buying a new set is cheaper than professional sharpening. When it comes to working with metal, particularly channel and pipe stock, you ll find a drill press is a godsend. It improves accuracy, and you ll find the work goes much faster. Always use a proper vise when working with a drill press. Never hold the work with your
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10.2 BUILD THE BUGGYBOT
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hands. Especially with metal, the bit can snag as it s cutting and yank the piece out of your hands. If you can t place the work in the vise, clamp it to the cutting table.
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10.1.4 BENDING
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One of the biggest challenges you will have when working with metal parts in your robots will be bending them accurately and evenly. When you go to your first robot competitions, you will no doubt see a few robots that look like they were run over by an eighteen-wheeler and hammered back into shape; hopefully you weren t critical; working metal into the desired shape is a challenge. So much so that when you first start working with metal on your own, you probably will want to avoid building robots that require any bent metal. It should not be surprising that different types of metals require different methods for bending. Steel bar stock, for example, can have a sharp angle bent into it by placing it in a vise at the point of the bend and then hitting it with a hammer to force the bend to the desired angle. Gentle bends in steel require more sophisticated tools; but you could use the equipment designed to bend steel for wrought iron fencing. Aluminum stock, on the other hand, is just about impossible to bend in a home workshop. Using the techniques described for bending aluminum will result in it cracking or even breaking off. If you must use aluminum, then you should either use bar stock cut and fastened together or have a piece of stock milled to the desired shape. Different forms of metal also are treated differently. The techniques previously discussed are not appropriate for sheet metal. Bending sheet metal is best accomplished using a sheet metal brake, which will bend the sheet metal (steel, aluminum, or copper) to any desired angle. Modest brakes can be purchased for about $100 from better machine shop supply houses (which you can find in the Yellow Pages).
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