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.
ADD IMAGE
Preparing CAM
ADD INFO
Milling
Machine was set to 2 AXIS mode which caused the machine to not move the Z axis while cutting. The machine was changed to 3 AXIS mode and this solved the problem
Turning
ADD INFO
Radial Indexing
ADD INFO
Manufacturing Defects
ADD INFO
Suggested manufacturing improvements
ADD INFO
Design Improvements
ADD INFO