Warpage/Distortion in Machining 7050-T7451 Alloy Components

Award Information
Agency:
Department of Defense
Branch
Air Force
Amount:
$99,993.00
Award Year:
2006
Program:
SBIR
Phase:
Phase I
Contract:
FA8650-06-M-5224
Award Id:
78833
Agency Tracking Number:
F061-087-2579
Solicitation Year:
n/a
Solicitation Topic Code:
n/a
Solicitation Number:
n/a
Small Business Information
111 West Port Plaza, Suite 825, St. Louis, MO, 63146
Hubzone Owned:
N
Minority Owned:
N
Woman Owned:
N
Duns:
859454886
Principal Investigator:
Sebastian Nervi
Research Engineer
(314) 744-5021
sebastian.nervi@esrd.com
Business Contact:
Steven Rancour
Chief Operating Officer
(314) 744-5021
steven.rancour@esrd.com
Research Institution:
n/a
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.

* information listed above is at the time of submission.

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