It started with an A4-sized spring steel sheet metal that's 0.05mm in thickness.
That's even thinner than your average paper.
It took me almost a month to fabricate several pieces of 30mm x 10mm x 0.0
5mm spring steel metal sheets as part of my Final Year Project (FYP) to build a whole new cantilever design and analyze the sensitivity associated with it. Not that it's difficult, but the queuing time was a killer. Because the NUS FSAE Race Car Team had priority over all the jobs in the CNC Fabrication Workshop, I was told my job would be ready after 3 weeks, since I wanted the wire-cut machine to be used, and only the workshop assistants knew how to operate it.So I waited. All of 3 weeks. That period so happened to be the IMF period, so I could still afford for such delay. Imagine, while my other friends were already getting their
hands dirty with hammering and sintering their project specimens, I still wasn't.And then, when it was finally done, it took some painstaking effort to screw 16 pieces of M2 x 3 screws manually into each cantilever, and all afternoon pasting strain gauges onto it. Then there was soldering of all the wires and connections to be done, even though we Mech Engin students were never officially given a lesson about the process.




BUT just today, when my Prof called me and my grad student advisor to a meeting at 3.30pm , he told us what the finalized plan with the external company I'm supposed to be collaborating with was. All along, the "discussion" my department had with this company hadn't generated positive results until now, when my Prof quoted them as saying, "funding anything we need to carry out the project." (Apparently the company has finally decided to fund this project since they want me/us to design, fabricate and test the system under various environmental conditions; so they seek FYP students like us to get involved.)
Instead of the cantilever re-design I started off with, my FYP is now the construction of a smaller, more portable tribometer which can fit inside a customized chamber (both of which I need to construct from scratch) so as to be able to measure 'hard disk' operations in a controlled environment where the temperature needs to be varied from -20 degrees Celsius up to 70 or 80 degrees, and the pressure and humidity varied too .
And that was me making up the synopsis of my FYP.
He showed me a sample of the hard disk, roughly the size of an SD memory card, except twice in thickness, and talked about the motivation for the project. Basically if this was to be put in a mobile phone, could it withstand the shocks, temperatures, pressures and humidity, for example, in a place like Mount Everest?
Sounds really interesting at first, but then the challenges set in.
While Prof was spewing out suggestions intertwined with instructions, thoughts of not graduating on time plagued my mind. So they (the ME Department and the company) waited 7 weeks until the tail-end of the mid-sem break to tell me what my actual FYP now encompasses? With 3 weeks left for my other Design Project (the Autonomous Robot Shooter) before the competition date and 2 other term projects due then, I didn't know what to make of this new task.
Questions aplenty, I might as well put it up here to remind myself what I have to find out, and possibly even receiving ideas from friends like yourself, since we never know when good suggestions might pop up.
1) First of all, it's gonna take a huge amount of time to start off all the Solidworks drawings and assemblies, to be made ready in 2 weeks time before the supposed meeting with the company representatives.
2) Fabrication of the parts takes ages, as I've learnt, along with decisions to use different materials for different purposes.
3) How do I build a double-insulated see-through chamber that allows me to pass wires through it into the computer for analyses?
4) How do I incorporate liquid nitrogen flowing into the chamber via copper tubes so as to keep the internal temperature at minus 20 degrees?
5) How do I devise and program a system where the valve can be automatically controlled as opposed to manual operation?
6) How do I construct a pump that reduces the pressure inside the chamber so as to simulate low pressure conditions like those in Everest?
7) Where can I get the wires and incorporate the tribometer and chamber into one so as to be able to control everything from one computer?
8) Where can I buy all these stuff to fabricate?
9) Where do I find time to do the research? And most of all,
10) How long is this going to take?????

In any case, the picture on the right shows what current tribometers in the lab looks like. The yellow encircled region indicates the cantilever portion I was supposed to study previously. How am I going to start from scratch?!?!
Somebody shoot me please.




















