Improved Titanium Machining Process

Machining is a major cost element in aerospace. High-speed machining (HSM) enables cost savings for aluminum components, but has not yet done so for titanium. Our Phase I results demonstrate feasibility of HSM and high-frequency tooth pass (HFTP)technology to overcome inherent titanium barriers and double metal removal rates (MRR) while maintaining tool life.To accomplish this dramatic improvement of titanium machining, we must apply HSM/HFTP techniques to titanium. Barriers include: (1) lack of validated analytical tools to reduce dependency on testing, and (2) high cost and inefficient methods for testingnew machining concepts. Our Phase II project approach develops advanced technology to achieve this, based on technology used in Phase I to identify regimes of titanium machining that promise MRR doubling.We will use the advanced modeling technology to demonstrate how process improvement barriers can be cost effectively reduced. Our demonstration consists of the following: (1) application of validated modeling technology specifically developed for metalcutting, (2) use of modeling techniques to significantly reduce need for testing while enabling implementation of new concepts, and (3) application of identified HSM/HFTP titanium machining regimes to military aerospace components provided by Boeing andSikorsky Aircraft to demonstrate MRR potential.