Machining of Complex Integral Airframe Structures

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8650-05-M-5213
Agency Tracking Number: F051-127-3135
Amount: $69,082.00
Phase: Phase I
Program: SBIR
Awards Year: 2005
Solicitation Year: 2005
Solicitation Topic Code: AF05-127
Solicitation Number: 2005.1
Small Business Information
AURORA FLIGHT SCIENCES CORP.
9950 Wakeman Drive, Manassas, VA, 20110
DUNS: 604717165
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Richard Guiler
 Senior Manufacturing Engineer
 (304) 842-8100
 rguiler@aurora.aero
Business Contact
 Kris Miller
Title: VP, Administration
Phone: (703) 331-1048
Email: kmiller@aurora.aero
Research Institution
N/A
Abstract
Currently the construction of complex aircraft structures such as the skeleton within a wing is extremely time consuming and expensive. Traditionally these structures are assemblies of sheet metal parts, machined parts and composite parts, which are bonded and riveted together. Replacing an assembly of this type with a single machined part has the advantages of reducing the total number of build hours, decreasing weight, and increasing strength, but the machining techniques used for this are very expensive. There have been a number of advances in machining techniques and equipment, which may allow an entire wing skeleton type of structure to be affordably machined as one piece with a minimal number of set-ups using much smaller machines. The combination of Plunge rough cutting, Sonically tuned milling equipment, Heat shrink coupling of cutting tools, Cutting tools designed with frequency in mind, Relieved cutting tools, and the use of High-speed fluid driven or gear driven right angle heads will allow smaller machines to build affordable complex integral aircraft structures from aluminum or titanium, like those found in aircraft such as the F-35A.

* information listed above is at the time of submission.

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