Improved Loaded Core Milling Process

Award Information
Agency:
Department of Defense
Branch:
Navy
Amount:
$150,000.00
Award Year:
2006
Program:
SBIR
Phase:
Phase I
Contract:
N68335-06-C-0140
Agency Tracking Number:
N053-145-0303
Solicitation Year:
2005
Solicitation Topic Code:
N05-145
Solicitation Number:
2005.3
Small Business Information
THIRD WAVE SYSTEMS, INC.
7900 West 78th St., Suite 250, Minneapolis, MN, 55439
Hubzone Owned:
N
Socially and Economically Disadvantaged:
N
Woman Owned:
N
Duns:
938966090
Principal Investigator
 Troy Marusich
 Chief Technical Officer
 (952) 832-5515
 troym@thirdwavesys.com
Business Contact
 Kerry Marusich
Title: President, CEO
Phone: (952) 832-5515
Email: sales@thirdwavesys.com
Research Institution
N/A
Abstract
Military aircraft utilize advanced materials like loaded core composites for superior strength, weight, fatigue and stealth properties in parts such as ailerons, flaps, runners, leading edges and rudders. While new processes like ultrasonic machining for cutting and shaping of loaded cores are an improvement over traditional milling methods to reduce dust, they are slow and suffer from rapid tool wear. Our Phase I project will demonstrate innovative loaded core milling modeling and process technology the Navy needs to reduce cycle time by 50% while maintaining or improving tool life. Teaming with Lockheed Martin, we will: (a) Apply physics-based modeling to address thermal, tool life and material removal rate (MRR) problems inherent in ultrasonic machining of loaded cores; (b) Meet program requirements by working with suppliers to achieve a 50% cycle time reduction; (c) Reduce scrap due to fraying and workpiece inaccuracies; (d) Eliminate trial-and-error testing; (e) Predict forces, temperature, tool wear and workpiece quality; and (f) Establish process parameters and tooling to improve MRR and tool life. Our three-phased development program will: (a) Demonstrate modeling for process representation; (b) Identify conditions for improved cycle time and tool life; and (c) Formulate a plan to integrate modeling and ultrasonic machining system.

* information listed above is at the time of submission.

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