Advanced Technologies for Discrete-Parts Manufacturing

Award Information
Agency:
Department of Defense
Branch
Defense Logistics Agency
Amount:
$99,944.00
Award Year:
2007
Program:
SBIR
Phase:
Phase I
Contract:
W9113M-08-C-0035
Award Id:
82350
Agency Tracking Number:
L072-001-0032
Solicitation Year:
n/a
Solicitation Topic Code:
n/a
Solicitation Number:
n/a
Small Business Information
7900 West 78th St., Suite 300, Minneapolis, MN, 55439
Hubzone Owned:
N
Minority Owned:
N
Woman Owned:
N
Duns:
938966090
Principal Investigator:
David Stephenson
Vice President, Engineering
(734) 340-3563
dave.stephenson@thirdwavesys.com
Business Contact:
Troy Marusich
Chief Technical Officer
(952) 832-5515
troym@thirdwavesys.com
Research Institute:
n/a
Abstract
Modern airframes require thousands of drilled holes in difficult materials such as graphite-epoxy composites, titanium, or layered metal-composite assemblies. Drill life and hole quality are often limited when drilling composites due to heat buildup. Drilling composite/metallic stackups often requires costly interlayer deburring due to rapid drill wear. Trial-and-error approaches to improving drilling processes do not yield optimum results due to cost and time limitations. In this project, analytical and numerical methods for designing composite and composite-metal stackup drilling processes, which will permit rapid investigation of a broader range of conditions, will be developed and validated. A finite element program specifically written for machining will be used with brittle fracture constitutive descriptions appropriate for composites. In Phase I, the feasibility of the approach will be established by developing a first stage, homogeneous constitutive description of fiber-epoxy composite, suitable for calculating bulk temperatures and stresses and for evaluating drill wear. Algorithms for assessing drill life based on computed temperatures and stresses will be developed and validated against drill life tests. A pilot process at an airframe plant will be used for further validation; a 100 percent increase in drill life will be targeted for this application application.

* information listed above is at the time of submission.

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