High-Speed Machining of Titanium Alloys Using Indirect Cutting Tool Cooling

The complexity of titanium (Ti-6Al-4V) firewalls and bulkheads for the V-22 rotorcraft demand the development of new, innovative fabrication technologies that enable high-speed machining (HSM) for affordability. Creare proposes to develop a novel, indirect cutting tool cooling system that will enable the increase of the material removal rate (MRR) by 500% or more for titanium milling. Such an increase in the MRR dramatically reduces the processing costs. For example, we have projected that our system would save approximately $800,000 per year in manufacturing cost for a titanium rotor yoke. Because our solution prolongs tool life, the resultant use of sharper tools will reduce the induced residual stresses in the machined part, improving fatigue life. Our innovation is readily integrated with existing machine tools, minimizing initial capital costs. Thus, our solution is effective, affordable, flexible, and easily integrated with current manufacturing operations.