High-Speed Headstock with B-Axis for Machining Aircraft Structures

The Air Force needs a compact high-speed high-power spindle to rapidly manufacture complex geometries in aluminum and titanium aircraft structures. We propose to continue developing a compact high-speed high-power spindle to meet Air Force requirements. In Phase I, we designed a pre-prototype spindle and calculated the operating characteristics of the spindle. Our design indicates our spindle is suitable for rapid manufacture of typical complex geometries in aircraft structures. Our performance calculations indicate our spindle can efficiently use the full supplied power for rapid machining. In Phase II, we will build the pre-prototype spindle and subject it to non-machining tests to characterize the spindle. Based on the tests, we will modify our design and performance calculations (as necessary), and we will design, build, and test (non-machining and machining tests) a prototype spindle. As a subcontractor, a major defense contractor will use the prototype spindle to machine sample parts. In Phase III, we will supply spindles (based on the prototype) to job shops that are machining aircraft structures for the Air Force.