Warpage/Distortion in Machining 7050-T7451 Alloy Components

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8650-06-M-5224
Agency Tracking Number: F061-087-2579
Amount: $99,993.00
Phase: Phase I
Program: SBIR
Awards Year: 2006
Solicitation Year: 2006
Solicitation Topic Code: AF06-087
Solicitation Number: 2006.1
Small Business Information
111 West Port Plaza, Suite 825, St. Louis, MO, 63146
DUNS: 859454886
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Sebastian Nervi
 Research Engineer
 (314) 744-5021
Business Contact
 Steven Rancour
Title: Chief Operating Officer
Phone: (314) 744-5021
Email: steven.rancour@esrd.com
Research Institution
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.

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

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