Precision Machining of Composite Structures

In this Small Business Innovation Research Phase I project, Precision Machining of Composite Structures, Third Wave Systems (TWS) will develop and demonstrate an innovative precision machining technique enabled by physics-based modeling, adaptive control machining and the generation of a machining digital twin the Navy requires to dramatically reduce machining-induced damage, improve manufacturing efficiency, and reduce consumable tooling cost by 50% during creation of finished precision fastener holes in aerospace composite structures. TWS’ approach will lead to the development of a cyber-physical system which integrates its physics-based modeling, NC toolpath optimization and data collection capabilities into a closed-loop adaptive control machining system. The system will monitor real-time force and temperature data, compare with an optimized digital baseline, and adjust the machining parameters to control machining-induced damage, optimize material removal rate and improve tool life. The resulting manufacturing data including temperature, forces, hole quality and dimensional accuracy will be retained and integrated into a part digital twin providing needed traceability of the part manufacturing process. The interoperability among machines, tools, sensors and people, a core design principle of Industry 4.0, will drastically improve quality control, increase manufacturing efficiency and reduce operational cost.