High-Speed Machining of Thin-Web, Large-Pocket Aircraft Components

The overall goal of our Phase II project is to demonstrate innovative, scalable high-performance machining (HPM) processes the Navy needs for thin-web, large-pocket aircraft components. The anticipated benefits of the program are the ability to apply physics-based modeling to predict and manage residual stresses leading to improved fatigue life, weight and distortion, and reduce labor costs and cycle time. We will demonstrate our innovative, scalable HPM process utilizing proprietary thermal management techniques in combination with machining modeling on V-22 and F-35 titanium components. Teaming with Bell Helicopter, Lockheed Martin and their suppliers we will develop and demonstrate physics-based modeling to achieve these results. We will enhance the modeling capability to integrate within the existing manufacturing environments, model baseline toolpaths for current part production, and demonstrate improvements in machining cycle time, residual stress management and part distortion.