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Improvements
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:
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The stock was clamped in the vice and the origin was set to the center of the part using an edge finder. After the tool table was created and the Gcode file loaded, we tried to run the operation, but the Z axis was not moving. We noticed that the machine was set to 2 AXIS mode which caused this problem and switching to 3 AXIS mode solved it.
Turning
Chucked on the mandrel made for the last bulkhead and indicated in. Indicated in to 4 thou of runout.
Significant chatter found at 1200 RPM, reducing the speed to 700 RPM yielded much better results until the last spring pass.ADD INFO
Radial Indexing
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Manufacturing Defects
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Suggested manufacturing improvements
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Design Improvements
- Broke an end mill on the rib pattern during a travel - oops
- Broke an end mill during the pass-through milling, raised a burr, filed out
- 10 thou thicker in the web than designed (.025 lbs heavier)
Suggested manufacturing improvements
- Leave stock on bottom face and remove on lathe to reduce chatter from pocketing operations
- Add chamfer mill path to break all corners
- Reduce 1/8 in end-mill feed rate to 6 IPM
- 1/4 in ball mill chatter, adjust feeds and speeds
- Model to include made to fit geometry.
Design Improvements
Maybe the best bulkhead we've ever made...ADD INFO