Warpage/Distortion in Machining 7050-T7451 Alloy Components

The machining of structures from materials such as titanium is typically accomplished using end mills and roughing 90 to 95 percent of the material to leave precise, complex features on thin walled structures. High speed machining is widely used in the manufacture of parts and reduces labor significantly. Single Cell Machining will be developed to produce structures which require machining and low stress grinding in a single cell with minimal operator input. Several approaches will be examined to produce required parts in a single cell while providing operators with the flexibility to implement different solutions depending upon equipment already in place. Three methods will be explored - NC lathes, mill/turn centers and multiple machines with robotic transfer assistance. Up to 60% unit cost reduction is projected for Single Cell Machining depending on material and part geometry.