Impovements
After machining the first Payload Bulkhead (SN 3), several suggestions for improvements were made to decrease weight and improve wire organization. This optimized version of the payload Bulkhead addresses these improvements by the following changes:
- Large pockets added to the face to reduce weight. The thickness in these reduced areas is now 0.050".
- Internal radii were increased increased from 0.0625" to 0.125". This increases strength and is more fitting for our tool availability.
- The rim thickness is decreased to 0.0625" in areas that do not have tapped holes.
- The large 0.875" dia hole was replaced by four holes that house connectors that will better organize the wires that pass through.
- The material was changed from 6061 to 7075-T651.
Creating Blank
Waterjet stock
Payload Bulkhead Stock Rev3.DXF is attached. This is the file that was used to waterjet the octagon blanks.
The stock was cut with 16 sides instead of 8 sides to reduce the amount of turning that would need to be done after the milling operations.
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Preparing CAM
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Milling
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Turning
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Radial Indexing
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Manufacturing Defects
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Suggested manufacturing improvements
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Design Improvements
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