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The cantilever consists of more than 100 different parts, such as casings, pallets, brackets, bolts, tethers, splints, etc. It also consists of three different parts: the front part is a 12" (304.8mm) diameter tubular part, at 40 "(1,016mm) stores all electronic components; the middle portion at 40" is the critical position for cracking because it bears the maximum stress; all cameras and sensors are placed at the tail of 96" (2,438.4mm).
Every part involved in this project has strict tolerances (typically in the 7.62 μm range) and strict surface roughness requirements. Old Reil said: "We ensure that these parts are machined on the highest precision equipment and equipped with our best team and tools."
In this case, the team was led by technician Adam Peek Blair and used tools from Seco Canada. Peek Blair said: "For OBSS, the vast majority of parts are made of 7075 aluminum. I rely on only two types of tools to do most of the machining tasks: the high-stretched equipment for the long-extension CombimasterTM system Round insert milling cutters and Nano Turbo pocket whirlwind mills equipped with the CombimasterTM system for clearing corners and machining uneven points."
The front mounting tray, mounted in the OBSS fitting and assembled with the ISA1, is designed to house all cameras and electronics and is approximately 70" (1,778 mm) long x 20" (508 mm) wide. The first machining process consisted of roughing the aluminum alloy material to a specific thickness and cutting 36 cavities with a length ranging from 3" to 6" (76.2-152.4 mm) and a width of 12" (304.8 mm). "I only I hope to remove the material as quickly as possible,†says Peek Blair. “The diameter of the 1†(25.4mm) round insert milling cutter with the T250M grade blade is ideal for that process.â€
With a depth of cut of 0.125" (3mm), a feed rate of 120in/min (3048mm/min) and a machine speed of 7000-8000RPM, Peek Blair can complete the roughing of the entire blank in just two hours. Then he uses 1â„2" (12mm) And the 3/8" (10mm) Nano Turbo shoulder milling cutter clears the corners and finishes the cavity wall with a thickness of only 0.8" (20mm), requiring very light and extremely fast cutting.
The ISA1 part is more difficult to machine and has many long overhanging compartments for OBSS electronics. The initial machining required a cutting stroke (deep insertion milling of up to seven inches (177.8 mm)) to remove a lot of material. Peek Blair relies on the CombimasterTM tool holder system because it provides unmatched rigidity during machining.
Most machining requires high-feed ramp milling inside the part, using a 1.5" (40mm) Nano Turbo cyclone with a 620470 blade and a Combimaster holder featuring an Rn connection. Peek Blair says: "Pinch milling It is possible to remove more material more quickly, but it will probably exert too much force on the equipment and may affect the quality of the part. â€
Reil also found an additional useful feature. “With NanoTurbo, you don’t worry about it after you have finished the knife,†Peek Blair added. “It only takes a few hours to return and the processing is complete.â€
It seems illogical that such highly important parts can be left unattended, but Reil found that Seco's products do provide that level of reliability. “Shandong provides us with cutting tools and technical support so that we can deliver high quality projects like those required by NASA customers,†said Reil. “We see Seco as a key part of our team.â€
Seco assists Reil in taking off
The robotics team of MacDonald Dettwiler and his assistants was a developer at Canadarm Robotics, who came to Reil to help produce the spacecraft's orbital cantilever sensing system (OBSS). The cantilever will be mounted on the Space Shuttle Discovery. When entering the orbit, the robotic arm will manipulate the cantilever to detect the type of damage that caused the Columbia to crash. When entering the orbit, the cantilever is placed at the end of the robot arm, twice as long as the original. A set of sensors, cameras and laser ranging systems are placed at the end of the cantilever and can be used by staff to view the damage.