High-Speed Machining of Thin-Web, Large-Pocket Ti-6Al-4V Firewalls/Bulkheads

Award Information
Agency: Department of Defense
Branch: Navy
Contract: N00421-04-P-0545
Agency Tracking Number: N041-013-0982
Amount: $129,624.00
Phase: Phase I
Program: SBIR
Awards Year: 2004
Solicitation Year: 2004
Solicitation Topic Code: N04-013
Solicitation Number: 2004.1
Small Business Information
7900 West 78th St., Suite 250, Minneapolis, MN, 55439
DUNS: 938966090
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Troy Marusich
 Chief Technical Officer
 (952) 832-5515
Business Contact
 Kerry Marusich
Title: President, CEO
Phone: (952) 832-5515
Email: sales@thirdwavesys.com
Research Institution
High performance aircraft structures have strict requirements regarding weight, strength and fatigue. The unitization of structures provides reduced labor costs, part count and improved quality while achieving desired weight requirements. Since firewalls are not part of the primary structure, they are typically made of built-up assemblies of thin plates, maximizing weight reduction. Chemical milling (CM) is used to create pockets however, this can be expensive, time consuming and environmentally unfriendly. Progress has been made in applying high-speed machining (HSM) techniques to titanium components via dynamic analysis, system stiffening and improved tooling. Yet application to firewalls is challenging since HSM can result in part distortion and unfavorable stresses not alleviated with shot peening. We will apply our innovative, scalable HSM process utilizing proprietary thermal management techniques in combination with machining modeling to V-22 firewalls. Teaming with Bell Helicopter, the monolithic design will result in dramatically reduced cycle time, cost, part count, and reduction or elimination of CM. The design of experiments testing will establish process boundaries and web thickness capabilities. Dynamic response analysis of the machine tool structure will identify appropriate stable process operating windows. Assessment of residual stresses and forces on part distortion will be made via model analysis.

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

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