Overview
The Hermes 2 nose cone tip is made of stainless steel, is also and follows a 3/4 power series (hypersonic optimum) shaped shape, like the nose cone (although work should be done to determine how accurately this can be approximated by a more simple curve for ease of manufacturing). The nose cone tip has one bolt hole in the center, and two angled holes (5 degrees from vertical) on either side for thermocouples so that valuable temperature data can be obtained during flight.
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CAM File: Nose Cone Tip (SLDW16).SLDPRT **IMPORTANT
Lessons Learned
- Make sure that whatever stock you order is long enough to account for not only the part, but 1" or more for the lathe to hold onto. If the part is too short, it might get damaged in the chuck, and machining will just be more difficult overall.
- Use the correct feeds and speeds for steel. Ask someone who has experience turning steel, and do research online to confirm.
- Drilling into steel is difficult, especially with a small drill bit. Use lots of lubricant and slow speeds, and expect drill bits to break.
- Order extra steel rounds in case you mess up one of them
Dimensions
- Total length (not including step):
- Diameter of step
- Base diameter
- Bolt hole dimensions
- Angled hole dimensions
- Mass
Manufacturing Steps
- Make simple jig to hold the stock at an angle for the angled holes. We used an angle of 5 degrees for our two angled holes.
- Drill bolt hole and two angled holes (slowly, lots of lubricant!)
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| Date | Material | Result | Lessons Learned | |
|---|---|---|---|---|
| March 6, 2019 | Stainless Steel | Thrown from chuck | Need a longer shank (only had around 0.5" for the chuck to grad onto- want at least 1") |  |
| March 8, 2019 | Aluminum | Not awful | Surface finish bad, SFM increased to 240, cutter engagement lowered | |
| March 16, 2019 | Stainless Steel | Finishing pass ruined part | Tool nose radius set in CAM -> set to zero in tool setup, roughing pass needs positive stock to leave. |  |
| March 18, 2019 | Aluminum | Finish pass still bad | Tip tool path still glitchy, removed finishing pass | |
| March 19, 2019 | Aluminum | Good! | Slower, +flood coolant | |
| April 1, 2019 | Aluminum | Part fell out of chuck | Coolant insufficient? Cut depth too high? weak chucking? Shank turned first! |  |
| April 7, 2019 | Stainless Steel | Tip broke off, part still flyable | Make sure you're using correct feeds/speeds for stainless steel |  |
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