Material: AL 6061

Purpose:

  • Four tapped holes for AV Bay rods

  • Pie cuts for mass reduction

  • Bulkhead is shaped to accommodate the aeroshells
  • Radial holes to attach to MPT
  • Shape allows for panels to pass through outside of bulkhead for avionics antennas to not have metal interference

Manufacturing Plan:

Step 1 - Waterjet top face profile:

  1. Lower size of holes on the top face by 0.005’’ to account for tolerance of waterjet before 

  2. Use Quality 3

  3. Set 2 tabs of width and height 0.1”

  4. Set thickness to 0.4’’

  5. Set material to Al 6061

Step 2 - Turn down part on lathe:

  1. Zero x and z offset on lathe to the edge of the diaphragm.

  2. Set the go-to of the x axis as the measured diameter of the part.

  3. Turn in 0.02in increments (more if you’re an expert) along the z axis until the diameter gets about 0.015in away from the required diameter (3.98 in). Then, turn down in increments of 0.005 in.

Step 3 - Tap rod holes with mill:

  1. Load the edge finder tool into the mill

  2. Set zeros on stock using edge finder

  3. Center mark four holes on top face

  4. Replace edge finder tool with a drill tip

  5. Set spindle speed to 1200 RPM

  6. Drill using a ¼-20 tap

  7. Replace drill tip with ¼-20 hand tap

  8. Use tap fluid liberally while tapping

  9. Hand-tapping: turn 1 cycle and then turn back half a cycle. If you feel resistance, turn backwards to remove excess material

  10. Continue tapping until the tap is visible on the other side

Step 4 - Radial Indexing:

  1. Properly set up radial indexer, ensuring sides are straight.

  2. Check that the first centered hole is aligned so that no holes will be drilled into the spokes.

  3. Attach the center drill tip and align the drill tip at the correct distance in order to mark the center holes.

  4. Set the spindle speed to 1200 RPM.

  5. After drilling the first center hole, rotate the part by 180 degrees and continue drilling center holes (2 in total). 

  6. Radial hole size: 8-32

  7. Replace center drill tip with drill tip and drill through all center-marked holes

  8. Use a tap-handle and center to tap holes with 8-32 tap on radial indexer (Refer to tapping holes section for tapping instructions

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