High Quality, High Productivity Composite and Multilayer Drilling

Award Information
Agency:
Department of Defense
Branch
Defense Logistics Agency
Amount:
$968,926.00
Award Year:
2009
Program:
SBIR
Phase:
Phase II
Contract:
W9113M-09-C-0203
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:
Troy Marusich
Chief Technical Officer
(952) 832-5515
troym@thirdwavesys.com
Business Contact:
Renee Brownlee
Finance Administrator
(952) 832-5515
renee.brownlee@thirdwavesys.com
Research Institution:
n/a
Abstract
Modern military and commercial airframes are comprised of aluminum, titanium and fiber reinforced composites mated together with rivets inserted in tens of thousands of pre-drilled holes. Drilling in assembly operations is performed on components made from stack-ups of composites, aluminum and titanium. Problems associated with hole quality, tool life and interlayer burrs are pervasive and result in costly destack and debur operations. Trial-and-error methodologies for improving drilling processes can be expensive, time consuming and have little guarantee of success. Development of new innovations has been hampered by empirical methodologies. It is therefore desirable to develop new physics-based modeling technologies for composite/metal stack-up drilling. Physics-based modeling will eliminate trial-and-error testing and enable the identification of process parameters and tooling to alleviate rework and scrap. Our Phase II program will further develop and demonstrate physics-based modeling for improved drilling processes of composite/metal stack-ups. Our Phase I results demonstrated model correlation to improved tool life and productivity. In Phase II, we enhance the constitutive model for composite workpieces and demonstrate improvements in conjunction with industry partners. Physics-based models will allow detailed analysis of new drill designs and process parameters, predict forces, temperature and hole quality, and ultimately reduce costs and cycle time.

* information listed above is at the time of submission.

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