Improved Loaded Core Milling Process

Military aircraft utilize advanced materials like loaded core composites for superior strength, weight, fatigue and stealth properties in parts such as ailerons, flaps, runners, leading edges and rudders. While new processes like ultrasonic machining for cutting and shaping of loaded cores are an improvement over traditional milling methods to reduce dust, they are slow and suffer from rapid tool wear. Our Phase I project will demonstrate innovative loaded core milling modeling and process technology the Navy needs to reduce cycle time by 50% while maintaining or improving tool life. Teaming with Lockheed Martin, we will: (a) Apply physics-based modeling to address thermal, tool life and material removal rate (MRR) problems inherent in ultrasonic machining of loaded cores; (b) Meet program requirements by working with suppliers to achieve a 50% cycle time reduction; (c) Reduce scrap due to fraying and workpiece inaccuracies; (d) Eliminate trial-and-error testing; (e) Predict forces, temperature, tool wear and workpiece quality; and (f) Establish process parameters and tooling to improve MRR and tool life. Our three-phased development program will: (a) Demonstrate modeling for process representation; (b) Identify conditions for improved cycle time and tool life; and (c) Formulate a plan to integrate modeling and ultrasonic machining system.