Precision Machining of Composite Structures

In this Phase II project, Third Wave System will further advance the innovative technologies and methodologies to develop a fully functional prototype of physics-based simulation and optimization solution for countersunk fastener hole drilling in composite structures. TWS will develop and validate physics-based countersunk fastener hole drilling simulation capability predicting cutting force, temperature, heat energy, and damage during the drilling process. Innovative damage and temperature optimization technology will be developed to minimize damage while maximizing hole making rate. TWS will also develop a closed-loop adaptive modeling technology incorporating real-time machining feedback to ensure high and consistent hole quality throughout drilling processes and improve tool life. Throughout the project, TWS will demonstrate the developed technology with verified industry baseline materials and cutting conditions. A Non-destructive Inspection technology will be used to measure the hole quality and compare it with the quality of hole machined by a conventional process. The anticipated benefits of this project include a 50 percent reduction in countersunk hole machining cost; minimized damage, high placement accuracy, reduced consumable tooling cost, and optimal hole making; and consistent part quality and high productivity. TWS will also work an industry group to collect feedback, identify gaps, and develop commercialization plans.