Machines Needed:
Lathe, Mill, Radial Indexer, Taps, Waterjet
Order of Operations:
0.) Procure Aluminum 6061 Stock. Please try to have the thickness be as close as possible. Create a machining drawing to help hasten the process.
1.) Resize CAD to compensate for waterjet imprecision. This should be on the order of 0.1 to 0.2 inches. This will be a purely radial increase.
2.) Waterjet the part. Add tabs where necessary and validate the path to avoid creasing and double cuts.
3.) Thread the center hole in a lathe. This may be done with the aid of the reverse function. Alternatively, a radial indexer may be used here.
4.) Shave off excess tabs with the lathe.
5.) Position in a vertical-bed mill and place the lateral/flat-side holes where we interface with the AV Panels. You may zero the surface to ensure flatness with parallels or with a deflection gauge.
6.) Repeat the process for all 3 sides of the piston mount.
7.) Place in a radial indexer either by screwing it onto the prison or finding some other method of extrusion where necessary. Mark out the holes expected positions on the physical part to aid the process, and guide holes may be helpful sanity checks.
Critical Points:
1.) Ensure correct placement of the radial/circumference-wise holes where the part interfaces with the mission package tube. The AV Panel holes may be amended where necessary, as those will be drilled by hand, but the MPT holes are essential.
2.) When drilling holes for threads, drill to at least 1.5 times the depth of the threading length to ensure full thread engagement.
3.) If you use overly thick stock, facing may be necessary. Ideally, to 0.38 inches, or the minimum length needed for full thread engagement with the piston.
4.) The iteration of this CAD used for the Phoenix JAN-23 launch is available in the Structures SubTeam Slack.