High-Speed Headstock with B-Axis for Machining Aircraft Structures

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8650-05-M-5207
Agency Tracking Number: F051-127-3613
Amount: $100,000.00
Phase: Phase I
Program: SBIR
Awards Year: 2005
Solicitation Year: 2005
Solicitation Topic Code: AF05-127
Solicitation Number: 2005.1
Small Business Information
3319 21st Ave NW, Gig Harbor, WA, 98335
DUNS: 054758185
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Douglas Beck
 Engineer
 (360) 876-9710
 dbeck23@aol.com
Business Contact
 Douglas Beck
Title: President
Phone: (360) 876-9710
Email: dbeck23@aol.com
Research Institution
N/A
Abstract
The Air Force needs new higher productivity, higher accuracy equipment and processes for machining integral, complex aircraft airframe structures cost effectively. Structures with simply shaped pockets and straight walls can be effectively end milled using large high velocity machine tools. However, these machines cannot efficiently mill structures with integral return flanges and other complex internal features. We propose to develop a High Speed Headstock with B-Axis (HSHBA) that will enable large high velocity machine tools to efficiently mill complex internal features. Our HSHBA mounts in the spindle nose of the large machine tools. Our HSHBA allows the cutting tool to be positioned with complex motions on a small scale while utilizing the large-scale motions of the high-velocity machine tool. The HSHBA also enables rapid end milling even when small tools with less than ¼" diameter are used because the miniature headstock rotates at up to 150,000 rpm and can deliver up to 5 horsepower of power to the small cutting tool. In Phase I, we will design a pre-prototype HSHBA and calculate its operating characteristics. In Phase II, we will build and test a prototype HSHBA. In Phase III, we will sell HSHBAs in the aerospace manufacturing market.

* Information listed above is at the time of submission. *

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