Machining Parameters for Direct Digital Manufacturing (DDM) of Aerospace Components

ABSTRACT: Morris Technologies, Inc of Cincinnati, Ohio, proposes a Phase I SBIR investigating proper grinding parameters for direct metal laser sintered [DMLS] components. This research is necessary to continue in the commercialization of DMLS, a high detail resolution direct digital manufacturing [DDM] technique. The objective of this project is to demonstrate the viability of the DDM, beginning with the DMLS process and developing grinding parameters which will not alter the DMLS part microstructures. Metrics will be defined for measuring the effectiveness of such grinding parameters, proposed standards and grinding methodology. An intelligent optimization scheme, concept analytical tool, will be researched and prototyped with the intent of determining viability of reducing qualification cost and times. Anticipated results include complete parameter sets [grinding wheel type, material, speeds, feeds, coolant types, etc...] for two commonly used aerospace superalloys: Titanium and Inconel. Like castings, forgings, and bar stock components, DDM components will require grinding processes to meet he tight tolerances required of the aerospace industry. The unique short grain structure of DMLS parts is different than that of conventionally manufactured parts and requires study. Safe grinding parameters will accelerate the acceptance of additive manufactured components in the aerospace and defense industry. BENEFIT: Safe parameter sets for the grinding of DMLS direct digital manufactured parts. The guidelines are necessary for the commercialization of this exciting additive technology. Safe grinding methodologies will ensure that metal microstructure and material properties are not adversly effected by industrial grinding.