University of Colorado Boulder



Colorado Space Grant Consortium

DemoSat 2010

Design Document

Alternative Energy Sat

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Written by:

Tyler Faucett, Paul Scholz, Michael Somers, Abby Wilbourn

6/30/2010

Revision C

Table of Contents

1.0 Mission Overview 3

2.0 Requirements Flow Down 3

3.0 Design 4

4.0 Management 8

5.0 Budget 10

6.0 Test Plan and Results 12

7.0 Expected Results 18

8.0 Launch and Recovery 18

9.0 Appendix 19

1.0 Mission Overview

In recent years wind and solar energy has become a much larger part of energy production, and new technologies and methods are constantly being developed including high altitude energy collection. The Mission of this experiment is to discover the optimum altitude and conditions at which solar and wind energy can be collected, as well as the optimum altitude for both to be collected together. The reason for this is to see if high altitude energy collection is worthwhile. The question that needs to be answered is whether the added cost and complication of installing high altitude solar and wind energy collection can be made up for by an increase in efficiency and production.

2.0 Requirements Flow Down

The top level requirements of this experiment are to measure and record wind speed and solar panel power throughout the duration of the flight, and from our flight data, be able to find a relationship between solar and wind power as a function of altitude. The next level of requirements is to measure and record outside temperature, pressure, and acceleration in the plane perpendicular to gravity. The relationships can be made more accurate with these readings. With temperature and pressure several parameters can be found such as altitude and air density. With the acceleration information the speed of the balloon can be found. This is important because wind speed can only be measured relative to the balloon. If both balloon speed and wind speed relative to the balloon are known then total wind speed in the horizontal plane can be found. Lastly it should be expected that solar and wind collection will depend on more than just altitude. Solar panel efficiency may be affected by temperature, and wind collection is definitely affected by air density. Because both temperature and pressure are being measured air density can be calculated. With these parameters the desired experiment relationships can be found more accurately.

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3.0 Design

The design for this project is one that will complete all of the necessary objectives as well as meet all of the requirements for the DemoSat program. Our basic structure consists of a central aluminum frame surrounded by a cylinder of foam board insulation. On the outside of the foam board there is a carbon fiber shell to provide strength to the structure upon the landing impact. The flight string will pass through the center of the structure inside a carbon fiber tube.

Almost all of the force on the payload will be passed through the aluminum frame to which the carbon fiber tube is bonded to. The aluminum frame will be strong enough to withstand any of the accelerations that the payload will experience during the flight. The outside cylinder made of foam board insulation will not only provide excellent thermal insulation, but will also, in combination with the carbon fiber shell, provide an excellent crash structure for when the payload lands. Inside the payload there will be a mounting plate made from lightweight 1/8” HDPE that is mounted to the aluminum frame. This will provide an easy way to mount all electrical components securely inside the payload.

For measuring solar power the payload will have three flexible solar panels wired in parallel with one another wrapped around the outside of the payload. These panels will almost cover the entire circumference of the payload. In this way the solar flux received from the panels should be the same regardless of the orientation of the payload on the flight string. A cup type anemometer will also be placed on the top of the device and will be mounted to the aluminum frame to allow it to withstand the high forces from the wind. It will also be placed high enough above the top that it will be outside of the boundary layer formed by the flow over the payload. Temperature and pressure will be measured outside the payload through small holes in order to minimize heat loss.

All sensing devices will be controlled using a PIC microcontroller which will take in data and send it serially to an SD card for safe data storage and collection. Data points will be collected every five seconds during the flight.

Temperature will be maintained using small flexible heaters which require little power to run. These heaters are also easily placed because of their flexibility, allowing the heat to be applied to areas and components that need it most inside the payload.

Electronic System Functional Block Diagram

|Parts List |Material/ Part Name |Source |Cost |

|  |  |  |  |

|Top Plate |1/16" 6061 AL |Metal Distributors |$14.27 |

|Bottom Plate |1/16" 6061 AL |Metal Distributors |0 |

|Structure Tube |1" X .125" Wall Al Square Tube |Metal Distributors |$4.20 |

|Foam Board |.5" Owens Corning Insulation |Home Depot |$13.68 |

|Epoxy |Loctite 5 min. set epoxy |Home Depot |$5.00 |

|CF Outer Shell |CF Cloth, Resin, Hardener |ACP Composites |$103.00 |

|Studs |.75" Acrylic Square |Fort Collins Plastics |$6.00 |

|Nuts |.75" Acrylic Square |Fort Collins Plastics |$0.00 |

|Mounting Plate |1/8" HDPE |Fort Collins Plastics |$4.26 |

|CF Tube |.281"OD X .186" ID |ACP Composites |$9.00 |

|Tube Fitting |1/2" X 1" 6061 AL Bar |Metal Distributors |$2.30 |

|Temp Sensor |SEN-00245 |Spark Fun |$4.25 |

|Pressure Sensor |480-1915-ND |Digikey |$35.95 |

|Pic Microcontroller |PIC16F884 |mircochip direct |$16.08 |

|Solar Panels |05-1293 |Silicon Solar Inc |$136.73 |

|Heaters |G16346 |Electronic Goldmind |$19.50 |

|Anemometer |WS25 |Inspeed |$61.35 |

|SD Card |144220 |micro center |$27.96 |

|SD Card Reader |BOB-00204 |Spark Fun |$28.02 |

|Battery |  |  |  |

|Various Resistors |Various |Radioshack |$10.00 |

|Various fasteners |Various |Ace Hardware |$5.00 |

|Accelerometer |SEN-00848 |Spark Fun |$35.23 |

|Switches |COM-09276 |Spark Fun |$1.95 |

|Protoboard |276-170 |Radioshack |$8.97 |

|Accel Mount |1" Acrylic Square |Fort Collins Plastics |$1.00 |

4.0 Management

At the start of this project all of the necessary tasks to complete the project successfully were listed out. Then these tasks were laid out into a reasonable order in which they were to be completed. Lastly it was decided upon which tasks needed to be completed before others could begin. All of this information was combined with the schedule of the project deadlines to produce a Gantt chart. Tasks were then divided and given to certain people based on skill set, and equal workload. The Gantt chart is shown below with important dates and responsibilities. At the present time the project has completed manufacturing and structural testing, and we are continuing with our electronics and programming.

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|DemoSat-B 2010 Summer Schedule |

|Objectives and Constraints Due |5/18/2010 |

|Project Plan Due |5/21/2010 |

|Modes of Failure Due |5/26/2010 |

|Kick-Off Telecon |6/8/2010 |

|PDR Slides Due |6/11/2010 |

|Design Document Rev. A/B Due |6/11/2010 |

|PDR Teleconference |6/14/2010, 1:00pm MDT |

|Manufacturing Complete |6/23/2010 |

|CDR Slides Due |6/24/2010 |

|CDR Teleconference |6/25/2010 |

|Design Document Rev. C Due |6/30/2010 |

|Progress Report Due |7/1/2010 |

|Test Readiness Review |7/8/2010 |

|First Full Mission Test Results Due |7/16/2010 |

|LRR Slides Due |7/26/2010 |

|LRR (Boulder ??) |7/30/2010 |

|Launch |7/31/2010 |

|Design Document Rev. D (Final Reports) Due |8/5/2010 |

5.0 Budget

|Money Budget |  | |Weight Budget |  |

|  |  | |  |  |

|Materials |Cost | |Parts |Mass (g) |

|cup anometer |$61.35 | |Aluminum Frame |301.81 |

|Foam Insulation |$13.68 | |CF/ Foam Tube W/ Studs |553 |

|Solar panels |136.73 | |Mounting Plate |96.4 |

|temperature sensor |$8.50 | |Stud Nuts |6.7 |

|pressure sensor |$35.95 | |Tube Fitting |15 |

|PIC16F884 |$16.08 | |CF Tube |13.75 |

|switch |$3.90 | |Cup Anemometer |100 |

|Heater unit |$19.50 | |Solar Panels |90 |

|protoboard |$8.97 | |Temp Sensor |0.5 |

|batteries |$80.00 | |Pressure Sensor |2.6 |

|dry ice |$60.00 | |PIC |6.7 |

|SD card reader |$28.02 | |SD Card and Reader |13.2 |

|SD card |$27.96 | |Proto Board with Circuitry |50.5 |

|resin/hardener |$64.00 | |Battery |150 |

|cf cloth |$39.00 | |Heaters |26 |

|1/2x1 6061 flat |$2.30 | |Switches |10 |

|1x1x1/8 6063 sq tube (qty 2) |$4.20 | |Fasteners |50 |

|12x24x1/8 5052 sheet (qty1) |$14.27 | |Accelerometer |2.9 |

|3/4 acrylic square rod (qty 2ft) |$6.12 | |Accelerometer mount |6.25 |

|1 quart cup |$1.49 | |  |  |

|small squeegee |$1.00 | |  |  |

|large squeegee |$0.85 | |Total |1495.31 |

|Stirrer |$0.20 | | | |

|1" Brush |$0.90 | | | |

|3" Brush |$1.05 | | | |

|8oz Cup |$0.50 | | | |

|cf tube |$9.00 | | | |

|accelerometer |$35.23 | | | |

|1/8" HDPE |$4.26 | | | |

|WaterJet time |$30.00 | | | |

|fasteners |$5.37 | | | |

|steel plate |$10.78 | | | |

|fiberglass rod |$2.73 | | | |

|acrylic square |$1.00 | | | |

|sand paper |$10.63 | | | |

|isopropyl alcohol |$2.65 | | | |

|cord |$3.99 | | | |

|clear coat |$3.24 | | | |

|battery 9v |$2.67 | | | |

|CF tube #2 |$15.00 | | | |

|Total |$758.07 | | | |

6.0 Test Plan and Results

The payload will be run through many tests before it is deemed flight ready. There are many structural tests that are outlined in the DemoSat user’s guide. A test structure will be built in order to complete all of the structural tests with. The tests include the whip test, stair pitch test, and the drop test. The test structure will be fitted with ballast placed in specific locations in the payload in order to simulate the weight of the equipment for the tests.

The whip test was performed on our test structure multiple times and all of these trials were filmed. After looking at the frame by frame of the video an angular velocity of 60 rpm was calculated. With this data and the known length of rope an average radial acceleration was calculated to be 8.2g. This acceleration would be higher when the directional change is imparted but an actual number is impossible to calculate.

Whip Test Picture

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The next test performed was the stair pitch test. In this test the test structure was kicked down a flight of 13 7.25 inch high by 10.5 inch long steps. During this test one of the three acrylic posts snapped off during the tumble. However the payload as a whole stayed together quite well, and we are confident that the internal components would have survived such an incident.

Stair Pitch Test Picture

One of the more rigorous tests performed on the payload was the drop test. In this test the payload was dropped from a height of 22.3 ft down to concrete below. The payload landed semi sideways with the top angled towards the ground. The top plate absorbed a considerable amount of energy as it yielded in several locations. The foam also absorbed some and there was a piece that broke away. Overall it seemed promising that the payload did not bounce on impact and stayed together for the most part.

Drop Test Pictures

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The last test performed on the payload was a second version of the whip test where the payload was dropped from a balcony while attached to a 10 ft rope to stop the fall. It is almost as if the payload was being hung. This test is better at imparting a sudden directional change to the payload than the other whip test. The test was performed in both vertical orientations. No damage was observed from this test.

Second Whip Test Picture

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Environmental tests will also be conducted using the actual sensors and electronics. These tests will include a cooler test for both the payload and the solar panels, as well as a bench test for the payload where it will be run for an amount of time equivalent to a full flight, roughly 150 minutes, and data will be collected.

Calibrations will also be performed on all sensors as well as the solar panels. The solar panels will go through full sunlight testing and testing in the shade, as well as cold tests to account for temperature. The anemometer will be tested on the ground as well so that an accurate measure of wind speed can be calculated from the instrument’s pulse count.

The cold test for the solar panels was performed with a mini fridge a desk lamp and a thermocouple with a digital readout. The solar panel was placed directly under the desk lamp inside the mini fridge, and the thermocouple measured the air temperature directly below the solar panel. Measurements were taken after every 2 degrees Celsius of temperature drop, until the lowest achievable temperature was reached at -18 C. Issues we encountered during the test were icing of the panel, and difficulty reaching such low temperatures. Relationships from our data as well as photos from the test are below.

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7.0 Expected Results

After the flight many relationships will be formed from the data. The most important of these will be wind speed and solar power as a function of altitude. It is expected that wind speed will be the highest in the middle of the jet stream. It is also expected that power from the solar panels will rise with increase in altitude and a sharp spike up will be seen above 30,000ft when the clouds dissipate. What is relatively unknown is how high the power from the solar panels will go, and if it will reach a max value.

8.0 Launch and Recovery

Every member of the team is scheduled to fully partake in the launch recovery and data retrieval for the payload. At the start of the flight the payload will be powered on by a member of the team. After a certain amount of time has passed roughly 120 minutes the data retrieval program will stop running on the pic. The payload will be tracked down using the data from NASA’s tracking payload. Paul will bring his camera to document the landing and condition of the payload. After the payload is brought back to Ft. Collins the sd card will be removed and the data will be downloaded to a computer. The data will then be put into excel, and the relationships that are desired will be found. A sample of the balloon speed calculation from the accelerometer is shown below for an accelerometer sampling rate of once per second.

9.0 Appendix

Drawings-

Process Sheets-

ACCELEROMETER MOUNT

PROCESS FAMILIES NEEDED

• SEPARATING

• FINISHING

TOOLING NEEDED TO COMPLETE PART

• COUNTERSINK

• ½” END MILL

• #43 TWIST DRILL

• 4-40 TAP

• CENTER DRILL

• SAND PAPER

PROCEDURE:

SAWING

1. OBTAIN 1” BY 1” PLASTIC ROD

2. CUT ON HORIZONTAL BAND SAW TO 1”

MILLING

1. GRIP WORKPIECE IN VISE ON MILLING MACHINE

2. PUT 2-FLUTE ½” END MILL IN COLLET

3. FACE BOTH SIDES OF PART THEN FACE TO LENGTH

4. EDGE FIND AND SET COORDINATES

5. CENTER DRILL ALL HOLES

6. DRILL HOLES THROUGH TO SPECIFIED DIAMETER

7. COUNTERSINK ALL HOLES

8. REGRIP IN VISE 90 DEGREES FROM PREVIOUS POSITION

9. EDGE FIND AND SET COORDINATES

10. USE ½” END MILL TO MILL STEP IN PART

FINISHING

1. USE FILE AND COUNTERSINK TO REMOVE BURRS AND PUT SMALL CHAMFERS ON ALL EDGES.

BOTTOM PLATE

PROCESS FAMILIES NEEDED

• SEPARATING

• FINISHING

TOOLING NEEDED TO COMPLETE PART

• COUNTERSINK

• 10-32 TAP

• SAND PAPER

PROCEDURE:

WATERJETTING

3. OBTAIN PART FILE NAMED BOTTOMPLATE36.

4. SAVE AS A DXF

5. WHEN WRITING CODE CHANGE TOOL OFFSET TO CUT AROUND THE OUTSIDE OF OUTSIDE LINES, AND TO CUT INSIDE OF HOLES

6. CUT OUT PART FROM .125” THICK AL ON WATERJET

TAPPING

1. REMOVE FROM WATERJET AND COUNTERSINK THEN TAP ALL HOLES INDICATED IN DRAWING.

FINISHING

2. USE FILE TO REMOVE BURRS AND PUT SMALL CHAMFERS ON ALL EDGES.

3. POLISH PART USING HIGH GRIT SAND PAPER.

PROCESS FAMILIES NEEDED

• SEPARATING

• FINISHING

TOOLING NEEDED TO COMPLETE PART

• HAND COUNTERSINK

• SAND PAPER

PROCEDURE:

SAWING

7. OBTAIN CARBON FIBER TUBE

8. CUT ON ABRASIVE CHOP SAW TO 15”

SANDING

4. SET A CALIPER TO THE DESIRED LENGTH SPECIFIED IN DRAWING

5. USE A BELT SANDER TO REMOVE MATERIAL UNTIL TUBE FITS PERFECTLY IN CALIPER JAWS

FINISHING

1. USE SAND PAPER TO ROUGH SURFACES THAT ARE TO BE BONDED

2. REMOVE ANY BURRS OR STRAY FIBERS

INSULATION CYLINDER

PROCESS FAMILIES NEEDED

• SEPARATING

• FINISHING

• BONDING

TOOLING NEEDED TO COMPLETE PART

• SPREADER

• BRUSH

• MIXING CUPS

• SCISSORS

• MASKING TAPE

• 1” HOLE SAW

• 1/8” TWIST DRILL

• 3/8” TWIST DRILL

• HOT WIRE CUTTER

• SAND PAPER

PROCEDURE:

HOT-WIRE CUTTING

9. OBTAIN PART FILES FOR CYLINDER SECTIONS

10. MAKE AND SAVE DRAWINGS AS A PDF

11. PRINT AND CUTOUT OUTLINES OF THE PARTS

12. TRANSFER THESE CUTOUTS TO TAGBOARD AND CUTOUT THE TAGBOARD FOR TEMPLATES

13. TRANSFER THE TEMPLATES TO THE FOAM BOARD WITH A SHARPIE

14. CUT THE CYLINDERS OUT USING A HOT WIRE FOAM CUTTER

DRILLING

1. MAKE SURE HOLES IN ALL FOAM PIECES ARE CLEARLY MARKED FROM THE TEMPLATE

2. DRILL THE THREE ALIGNMENT HOLES IN ALL FOAM PIECES TO 1/8”

3. DRILL THE THREE HOLES IN TWO CYLINDERS TO 3/8”

4. DRILL THE THREE HOLES IN ONE CYLINDER TO 1” USING A HOLE SAW

5. DRILL THE THREE ALIGNMENT HOLES INTO THE PLYWOOD

GLUING

1. BEGIN STACKING THE RINGS ONE BY ONE STARTING WITH THE TWO SOLID PIECES.

2. ALIGN EACH RINGS HOLES WITH THE FIBERGLASS RODS INSET INTO THE PLYWOOD

3. GLUE EACH RING AS YOU BUILD UP

4. AFTER THE 12TH RING HAS BEEN LAID CUT THE FIBERGLASS ROD OFF WITH .5” STICKING OUT

5. EPOXY ON THE THREE POSTS TO THE TOP OF THE 12TH RING AND TO THE FIBERGLASS ROD

6. PLACE THE LAST THREE RINGS ON EPOXYING TO THE POSTS AS YOU GO

SANDING

1. SAND OUTSIDE OF RING UNTIL IT IS ACCEPTABLY ROUND AND SMOOTH TO LAY UP ON

CUTTING CLOTH

1. MAKE TEMPLATES FOR EACH PIECE OF CARBON FIBER CLOTH USING THE PLOTTER

2. TAPE THESE TEMPLATES TO THE CF CLOTH SO THAT EACH CUT WILL BE TAPED ALONG.

3. CUT THE CLOTH TO THE SHAPE OF THE TEMPLATES USING SCISSORS

LAYING UP

1. MIX EPOXY AND HARDENER IN THE PROPER AMOUNTS BUT DO NOT MIX MORE THAN CAN BE USED DURING THE POT LIFE

2. WRAP THE FIRST PIECE OF CF CLOTH AROUND THE CYLINDER AND WET IT THROUGH WITH EPOXY USING SPREADERS AND BRUSHES. GOOD PENETRATION AND COVERAGE IS KEY.

3. PLACE THE TOP PIECE ON AND AGAIN WET THROUGH WITH EPOXY

4. WRAP THE SECOND PLY CLOTH AROUND THE OUTSIDE AND WET THROUGH

5. CHECK THE LAY UP TO SEE IF ANY AREAS ARE IN NEED OF MORE EPOXY AND APPLY AS NEEDED.

6. PLACE IN A WARM DRY ENVIRONMENT TO CURE

FINISHING

1. SAND OUTSIDE DOWN TO A SHINE

2. CUT OFF EXTRA FABRIC

3. COAT OUTSIDE IN A CLEAR COAT

MOUNTING PLATE

PROCESS FAMILIES NEEDED

• SEPARATING

• FINISHING

TOOLING NEEDED TO COMPLETE PART

• COUNTERSINK

• #32 TWIST DRILL

• #9 TWIST DRILL

• SAND PAPER

PROCEDURE:

SETUP

1. OBTAIN PRINTED PDF OF MOUNTING PLATE

2. CUT OUT OUTLINE AND IMPOSE OUTRER EDGES ONTO PLASTIC

3. CENTER PUNCH ALL HOLES

SAWING

15. OBTAIN ¼” HDPE

16. CUT OUTLINE ON VERTICAL BAND SAW

DRILLING

1. USE DRILL PRESS AND TWIST DRILLS MENTIONED ABOVE TO DRILL HOLES IN PART

FINISHING

6. USE FILE AND COUNTERSINK TO REMOVE BURRS AND PUT SMALL CHAMFERS ON ALL EDGES.

PLASTIC NUT

PROCESS FAMILIES NEEDED

• SEPARATING

• FINISHING

TOOLING NEEDED TO COMPLETE PART

• COUNTERSINK

• HSS LATHE TOOL

• 5/16 TWIST DRILL

• 3/8-16 TAP

• CENTER DRILL

• SAND PAPER

PROCEDURE:

LATHE TURNING

17. OBTAIN ¾” SQUARE PLASTIC ROD

18. CHUCK IN FOUR JAW CHUCK IN LATHE

19. FACE THE FRONT OF THE PART

20. CENTER DRILL THE HOLE

21. DRILL HOLE IN CENTER WITH SPECIFIED TWIST DRILL AS DEEP AS YOU CAN GO

22. TAP HOLE ON LATHE IN BACK GEAR AS FAR AS YOU CAN GO

SAWING

1. USE A HORIZONTAL BAND SAW TO CUT OFF PIECES OF SPECIFIED LENGTH IN DRAWING

2. REPEAT STEPS 2 AND 3 OF LATHE TURNING BETWEEN EACH CUT

FINISHING

7. USE FILE AND COUNTERSINK TO REMOVE BURRS AND PUT SMALL CHAMFERS ON ALL EDGES.

PLASTIC POST

PROCESS FAMILIES NEEDED

• SEPARATING

• FINISHING

TOOLING NEEDED TO COMPLETE PART

• COUNTERSINK

• HSS LATHE TOOL

• 1/8” TWIST DRILL

• 3/8-16 THREADING DIE

• SAND PAPER

PROCEDURE:

LATHE TURNING

23. OBTAIN ¾” SQUARE PLASTIC ROD

24. CHUCK IN FOUR JAW CHUCK IN LATHE

25. FACE THE FRONT OF THE PART

26. TURN DOWN THE POST TO .372” DIAMETER FOR THE LENGTH SPECIFIED

27. PUT A CHAMFER ON THE END OF THE POST

28. THREAD POST AS FAR AS YOU CAN GO IN BACK GEAR ON THE LATHE

SAWING

3. USE A HORIZONTAL BAND SAW TO CUT OFF PIECES OF SPECIFIED LENGTH IN DRAWING

4. REPEAT STEPS 2 THROUGH 6 OF LATHE TURNING BETWEEN EACH CUT

DRILLING ON LATHE

1. GRIP THREADED END OF POST IN THREE JAW CHUCK

2. FACE THE SAWED FACE

3. CENTER DRILL AND DRILL THE 1/8” HOLE INTO THE PART.

FINISHING

8. USE FILE AND COUNTERSINK TO REMOVE BURRS AND PUT SMALL CHAMFERS ON ALL EDGES.

STRUCTURE TUBE

PROCESS FAMILIES NEEDED

• SEPARATING

• FINISHING

TOOLING NEEDED TO COMPLETE PART

• COUNTERSINK

• #21 TWIST DRILL

• 10-32 TAP

• SAND PAPER

• ½” END MILL

PROCEDURE:

SAWING

29. OBTAIN 1” ALUMINUM SQUARE TUBE.

30. CUT TO 7” ON HORIZONTAL BAND SAW

MILLING

2. PUT IN MILL VISE WITH AN END STICKING OUT TO FACE OFF

3. CHUCK A 2-FLUTE ½” END MILL IN THE MILL

4. FACE BOTH ENDS

5. FACE DOWN TO LENGTH SPECIFIED IN DRAWING

6. EDGE FIND AND SET COORDINATE SYSTEM

7. CENTER DRILL BOTH HOLES SPECIFIED IN THE DRAWING

8. DRILL BOTH HOLES SPECIFIED IN DRAWING WITH A #21 TWIST DRILL

9. USE A COUNTERSINK TO PUT A SMALL CHAMFER ON BOTH HOLES

10. CHUCK ½” END MILL IN THE MILL.

11. CUT SLOTS IN TUBE AS SPECIFIED IN THE DRAWING

12. GRIP THE TUBE VERTICALLY IN THE VISE

13. EDGE FIND AND SET COORDINATE SYSTEM

14. MILL THE STEP INTO THE TUBE WITH ½” END MILL

15. REPEAT STEPS 11 THROUGH 13 FOR STEP ON OPPOSITE SIDE

TAPPING

1. REMOVE FROM MILLING MACHINE AND HAND TAP BOTH HOLES THROUGH TO 10-32

FINISHING

9. USE FILE TO REMOVE BURRS AND PUT SMALL CHAMFERS ON ALL EDGES.

10. POLISH PART USING HIGH GRIT SAND PAPER.

TOP PLATE

PROCESS FAMILIES NEEDED

• SEPARATING

• FINISHING

TOOLING NEEDED TO COMPLETE PART

• HAND COUNTERSINK

• SAND PAPER

PROCEDURE:

WATERJETTING

31. OBTAIN PART FILE NAMED TOP_PLATE

32. SAVE A DRAWING AS A DXF

33. WHEN WRITING CODE OFFSET LINES SO THAT THE PART WILL TURN OUT AS IT IS IN THE MODEL

34. CUT THE PART FROM .125” AL ON THE WATERJET IN THE SAME PROGRAM AS BOTTOM PLATE

FINISHING

3. USE SAND PAPER AND A FILE TO REMOVE BURRS

4. USE A HAND COUNTERSINK TO PUT A SMALL CHAMFER ON HOLES

TUBE FITTING

PROCESS FAMILIES NEEDED

• SEPARATING

• FINISHING

TOOLING NEEDED TO COMPLETE PART

• COUNTERSINK

• ½” END MILL

• ½” BALL NOSE END MILL

• #9 TWIST DRILL

• L TWIST DRILL

• CENTER DRILL

• SAND PAPER

PROCEDURE:

SAWING

35. OBTAIN ½” BY 1” ALUMINUM BAR

36. CUT ON HORIZONTAL BAND SAW TO 2.625”

MILLING

11. GRIP WORKPIECE WITH 1” DIM VERTICAL IN VISE ON MILLING MACHINE

12. PUT 2-FLUTE ½” END MILL IN COLLET

13. FACE BOTH SIDES OF PART THEN FACE TO LENGTH

14. EDGE FIND AND SET COORDINATES

15. CENTER DRILL ALL HOLES

16. DRILL HOLES THROUGH TO SPECIFIED DIAMETER

17. COUNTERSINK ALL HOLES

18. USE ½” END MILL TO MILL FIRST PART OF STEP ON BOTH SIDES

19. USE ½” BALL NOSE END MILL TO FINISH THE STEP INCLUDING THE FILLET.

FINISHING

11. USE FILE AND COUNTERSINK TO REMOVE BURRS AND PUT SMALL CHAMFERS ON ALL EDGES.

12. POLISH PART USING HIGH GRIT SAND PAPER.

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