Increased Production Yield of Carbon/Carbon Composites via Machining Optimization

In this program, the proposer will advance and demonstrate a cutting-edge physics-based modeling and process optimization technology to double the overall system throughput by dramatically reducing scrap associated with the finish machining operations for Carbon/Carbon (C/C) components. The proposed technology, which integrates advanced material modeling, multi-scale simulation of grinding process, and highly automated process optimization, will enable dramatic scrap reduction in the manufacturing of C/C hypersonic components by eliminating machining-induced damage and improving surface integrity. The mission impact of this program on the Department of the Air Force (USAF) and the Department of Defense (DoD) will be a significant increase of throughput and overall yield, a stronger and broader supply base to meet current and future demand for hypersonics, and a 50% or more cost reduction in C/C component manufacturing.