An Advanced Machining System for the Improved Manufacture of Aerospace Materials

Advanced propulsion systems for the Joint Strike Fighter (JSF) aircraft require the use of advanced materials for longer life, reduced weight, and increased performance. Ceramic matrix composite (CMC) materials have the potential to realize these benefits; however, the high cost of finished CMC components makes wide implementation impractical. To reduce these costs, new innovative fabrication technologies are required that enable substantial processing speed increases to drive down the expense of machining. Creare proposes to develop an advanced machining system (AMS) that will increase the processing speed for the machining of CMCs and other aerospace materials. During Phase I, we demonstrated that our novel approach can increase the processing speed by 80% or more for edge milling, which translates to a 45% decrease in part cycle time. We expect to exceed these results in Phase II. During the Phase II project, we will extend our innovation to pocketing, drilling, and countersinking and complete a technology demonstration on a representative geometry. During the Phase II Option, we will integrate our system onto an end-user’s machine tool. Our solution is effective, affordable, flexible, and easily integrated with current manufacturing operations.