High-Speed Machining of Thin-Web, Large-Pocket Ti-6Al-4V Firewalls/Bulkheads

The overall goal of our Phase II project is to demonstrate innovative, scalable high-performance machining (HPM) processes the Navy needs for thin-web, large-pocket Ti-6Al-4V firewalls and bulkheads. The anticipated benefits of the program are the ability to fabricate unitized structures resulting in reduced labor costs, part count and improved quality while achieving desired weight requirements and fatigue life. We will demonstrate our innovative, scalable HPM process utilizing proprietary thermal management techniques in combination with machining modeling to V-22 firewalls. Teaming with Bell Helicopter, we will develop monolithic designs that dramatically reduce cycle time and part count; and achieve cost and weight reductions needed for V-22. We enable cost-effective fabrication of thin-section unitized structural elements; provide affordable fabrication of bulkheads that meet qualification criteria; and address the special thermal and tool life problems inherent in titanium machining. Our technical program will push the performance envelope to achieve sections thinner than 0.030” for large pockets and thin webs. Thin-section features from V-22 parts will be integrated into a unitized test coupon for machining demonstration. Performance improvements in material removal rate between 200%-300% will be achieved and demonstrated on three V-22 thin-section parts. An optional task for kellering processes is included.