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

The Air Force needs new higher productivity, higher accuracy equipment and processes for machining integral, complex aircraft airframe structures cost effectively. Structures with simply shaped pockets and straight walls can be effectively end milled using large high velocity machine tools. However, these machines cannot efficiently mill structures with integral return flanges and other complex internal features. We propose to develop a High Speed Headstock with B-Axis (HSHBA) that will enable large high velocity machine tools to efficiently mill complex internal features. Our HSHBA mounts in the spindle nose of the large machine tools. Our HSHBA allows the cutting tool to be positioned with complex motions on a small scale while utilizing the large-scale motions of the high-velocity machine tool. The HSHBA also enables rapid end milling even when small tools with less than ¼" diameter are used because the miniature headstock rotates at up to 150,000 rpm and can deliver up to 5 horsepower of power to the small cutting tool. In Phase I, we will design a pre-prototype HSHBA and calculate its operating characteristics. In Phase II, we will build and test a prototype HSHBA. In Phase III, we will sell HSHBAs in the aerospace manufacturing market.