Novel Tooling for High Speed, Precision Machining of CMCs

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 make 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 and the cycle time of implementation for advanced materials. Creare proposes to develop an advanced machining system (AMS) that will increase the processing speed 100% or more for the machining of CMCs and other aerospace materials by leveraging existing programs with novel tooling approaches. Such an increase in the processing speed will dramatically reduce both overall cost and cycle time. Because our solution prolongs tool life, the resultant use of sharper tools will reduce the induced residual stresses in the machined part, improving fatigue life. Our innovation is readily integrated with existing machine tools, minimizing initial capital costs. Thus, our solution is effective, affordable, flexible, and easily integrated with current manufacturing operations.BENEFITS: Aircraft engine manufacturers will be able to significantly reduce the cost of machining advanced materials for military and commercial systems. The increased affordability of these advanced materials parts will expand the market for these materials into automotive, heavy equipment, construction, and consumer products.