Final Project for ME 203 - Design & Manufacturing
Description: A combined-function safety whistle capturing the beauty of the common mime butterfly, VIGA is a useable artistic piece conveying a message about pacifism and personal protection.
Processes: Pattern-Making, Sand Casting, Milling, Turning, Brazing, Press-Fitting
I made a number of whistles out of aluminum cans to observe whistle characteristics (air flow).
I used multiple PVC pipe whistles to look at whistle length/pitch and the fipple characteristics (angle, wooden insert length, height)/volume.
I tested the feasibility of specific processes, the primary focus being the method of connecting a cast-piece to a machined piece.
I decided to try working with OnShape's cloud-based CAD platform for this project - I found that it was missing a number of key features but enjoyed the convenience of working on the cloud.
an Onshape Drawing of the assembly
I carved modulan using belt sanders and rotary tools to create my pattern, gate, and runner, and the dimensions of the casting collars for the pattern board.
I fine-tuned the pattern for a smoother cast-finish (primarily addressing sand-wash using draft angle, a finer sanding grit, more layers of shellac).
Silver, with a lower melting point than brass and bronze, was the material I used to braze the parts; the cast bronze piece required more time to heat than the thinner-walled whistle body.
2 thou tolerance