Team Members:
- Jake Halpern
- Alex Speyer
- Nate Aquilio
- Brahm Soltes
- Tomasz Mazur
- Kenny Kim
- Alex Durand
- Mike Elrod
- Ryan Cross
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- Make Task List
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- Assign Roles
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- Make Timelines
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- FDR
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- Finalize CAD Drawings
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- Create Engineering Drawings
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- Make COTS Parts list + Order
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Schedule
1/21-22 - FG Prep/Wind
1/29 - Nose Cone Layup
2/4-5 - CF Prep/Wind
2/12-26 - Aluminum Tip/Bulkheads/Thrust Plate/Centering Ring
3/5 - Fin Cut
3/5-26 - Post-processing/Integration
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- 3 Fiber Glass Body Tubes
- CAD
- Engineering Drawings
- Wind Tubes
- Post-process
- sanding, paint, holes
- Test
- Integrate into Rocket
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CAD/ Drawings - Michael Elrod (RIT Student)
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- 1 Carbon Fiber Booster Tube
- CAD
- Engineering Drawings
- Wind Tubes
- Post-process
- sanding, paint, holes
- Test
- Integrate into Rocket / coupler
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CAD/ Drawings - Michael Elrod (RIT Student)
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- 4 Aluminum Bulkheads
- Add holes to CAD
- FEA
- Drawing
- Stock: Aluminum in basement
- Tool Path
- Tormach/cleanup
- Secured by Rocket Epoxy
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Mill
CAD/ Drawings - Michael Elrod (RIT Student)
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- 3 Plywood Centering Rings
- CAD
- Drawings
- Stock: Plywood
- Construct Router
- Integrate using rocket epoxy to CF Tube
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CAD/ Drawings - Michael Elrod (RIT Student)
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- Fins (including fin slots)
- Calculations
- CAD
- Drawings
- Stock (CF Sheets)
- Manufacture on router (Ask Mike) (water jet?)
- Integrate
- 3D print internal jig
- rocket epoxy fin to tube with jig in
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CAD/ Drawings - Michael Elrod (RIT Student)
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- Tip to tip layup (3-5 layers)
- Lay-up 4 layers of CF rotating weave 45 deg. each layer
- apply to rocket - overlap over edge of wing
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- Aluminum Tip
- CAD - need thread and washer to secure
- tool path
- Lathe
- Cleanup
- Integrate
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- FG Nose Cone
- Calculations
- CAD/Mold
- Engineering Drawings
- Mold
- Stock MDF
- Cut on the router
- sand
- gray
- sand
- Stock: Aluminum
- Cut stock
- layup
- post-process
- sanding
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- Rail Guides
- CAD
- Buy
- Integrate
- Connect to CF tubes with Nuts and Bolts
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CAD/ Drawings - Michael Elrod (RIT Student)
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- Boat Tail
- CAD
- send to Matt
- Get from Matt
- Bolted to Aft bulkhead
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CAD/ Drawings - Michael Elrod (RIT Student)
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- Thrust Plate
- CAD
- Drawing
- Stock - Aluminum
- tool path
- tormach/ cleanup
- rocket epoxy to CF tube
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CAD/ Drawings - Michael Elrod (RIT Student)
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Parts to Buy:
- 3 FG Coupler Tubes
- Rail Guides
- Motor
- Motor Casing
- FG Motor Tube
- Resin
- Hardener
- 5 min Epoxy
- Rocket Epoxy x2
- Fiberglass cloth
- Carbon Fiber Sheets
- Long Threaded Rod
- Washers
- Nuts
- Bolts
- Eyebolts
- Sanding materials
- Paint
Fiber Glass Body Tube Winding:
Setup -
- Clean the mandrel and wrap area being used in mylar (should wrap around at least twice). Secure with tape.
- Lay down paper on floor and over beam that runs underneath the mandrel to catch any epoxy drippage.
- Clean and insert rollers into plastic epoxy bath.
- Screw bath onto X-Winder using metal top plate.
- Clean and insert the remaining rollers, securing both ends of bolts to ensure there is no detachment during the wind.
- Feed selected tow over and around the rollers and out the front eyebolt.
- Attach cup underneath front eyebolt to catch any epoxy drippage.
- Insert squeegee and secure with rubber-band to ensure tight fit.
- Tighten nuts on both ends of the mandrel. Check all other nuts (rollers) to ensure they are fastened tightly.
- Ensure belts on motor and mechanism are tight enough to ensure there is no slippage.
- Connect computer and plug in machine.
- Check dimensioning on program.
- Zero the X-winder.
- Tape tow to mylar on mandrel.
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Winding -
- Mix a 6:1 ratio of epoxy in a dixie cup and pour contents into epoxy bath.
- Start the program.
Notes: Ensure the tow is overlapping previous lines slightly
Keep the speed of the tow on a medium speed for 60 deg. layers for best results
Refill Epoxy bath before it runs out to prevent dry spots
Only reuse epoxy in catch cup if contents has not started the hardening process
If there is a lot of built-up epoxy, the excess may be squeegeed off the tube carefully - only recommended on 90 deg layers, but possible on others.
If using an external lazy-suzan to feed tow, allow some slack between the roll and the rollers on the machine to prevent skipping.
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Removal -
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