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Warpage/Distortion in Machining 7050-T7451 Alloy Components

Award Information

Agency:
Department of Defense
Branch:
Air Force
Award ID:
78833
Program Year/Program:
2006 / SBIR
Agency Tracking Number:
F061-087-2579
Solicitation Year:
N/A
Solicitation Topic Code:
N/A
Solicitation Number:
N/A
Small Business Information
Engineering Software Research & Development, Inc.
111 West Port Plaza Suite 825 St. Louis, MO 63146-
View profile »
Woman-Owned: No
Minority-Owned: No
HUBZone-Owned: No
 
Phase 1
Fiscal Year: 2006
Title: Warpage/Distortion in Machining 7050-T7451 Alloy Components
Agency / Branch: DOD / USAF
Contract: FA8650-06-M-5224
Award Amount: $99,993.00
 

Abstract:

Investigation of the feasibility of development of a mathematical model that will have the capability to provide machine operators with specific guidelines for efficient machining, while minimizing any distortion and warpage, is the main objective of the proposed Phase I effort. The most challenging aspect of this project is the development of a validated mathematical model for the effects of machining-induced residual stresses (MRS). Previous investigation indicated that the influence of machining-induced residual stresses increases with decreasing part thickness. Furthermore, machining-induced residual stresses depend on tool sharpness, corner radii, machining pattern, feed rate and other controllable parameters. It will be necessary to develop a mathematical model capable of predicting the effects of end mill process parameters, specific to alloy and part geometry. MRS caused by metal cutting and grinding operations are confined to a very thin surface layer. Convincing correlation was found between tool diameter, tool sharpness, corner radii and machining pattern. These correlations are likely to be size-dependent and there is statistical variability, yet to be quantified. It is expected that the residual stress pattern is periodic.

Principal Investigator:

Sebastian Nervi
Research Engineer
3147445021
sebastian.nervi@esrd.com

Business Contact:

Steven Rancour
Chief Operating Officer
3147445021
steven.rancour@esrd.com
Small Business Information at Submission:

ENGINEERING SOFTWARE RESEARCH & DEVELOPMENT, INC.
111 West Port Plaza, Suite 825 St. Louis, MO 63146

EIN/Tax ID: 431517896
DUNS: N/A
Number of Employees:
Woman-Owned: No
Minority-Owned: No
HUBZone-Owned: No