Improved Landing Gear Grinding/Finishing Methods on Hard Wear Resistant Surfaces

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8222-11-C-0012
Agency Tracking Number: F093-203-0818
Amount: $481,822.00
Phase: Phase II
Program: SBIR
Awards Year: 2011
Solicitation Year: 2009
Solicitation Topic Code: AF093-203
Solicitation Number: 2009.3
Small Business Information
550 West C Street, Suite 1630, San Diego, CA, -
DUNS: 127283500
HUBZone Owned: N
Woman Owned: Y
Socially and Economically Disadvantaged: N
Principal Investigator
 Richard Straten
 HVOF Manager
 (801) 926-1150
Business Contact
 Doug Wiser
Title: Engineering Manager
Phone: (801) 926-1150
Research Institution
ABSTRACT: The Air Force is currently replacing chrome plating with High Velocity Oxygenated Fuel (HVOF) applied tungsten carbide-cobalt (WC-Co and WC-Co-Cr) coatings. These coatings require diamond wheels for finish grinding the HVOF coatings as well as aluminum oxide grinding wheels for base metal prep and Chrome plate grinding. The use of two types of wheels creates an undesirable equipment change during the overhaul and finishing process. In addition, the current use of both diamond and aluminum oxide grinding wheels involves the risk of grind burns to the substrate of landing gear components. In Phase I, ES3 demonstrated belt grinding technology can safely grind HVOF applied WC-Co coatings as well as High Strength Steel substrates (HSS) more economically than standard grinding wheels without burning the substrate material. In Phase I, only the infeed rate was varied. A full Design of Experiment will be performed in Phase II to determine optimal manufacturing parameters which will ensure maximum efficiency without creating grinding burns. All grinding parameters will be varied including in-feed, cross feed, part surface speed, and wheel surface speed. In addition, ES3 will prototype 3 additional grinders with belt grinding attachments located in building 507 Hill AFB. BENEFIT: The implementation of Belt Finishing will have a dramatic impact on the cost and efficiency within the DoD and commercial businesses. This improved grinding method has demonstrated exceptionally fast cutting removal rates, dramatically reduced times associated with belt changes over wheels, in addition the threat of grinding burns to the substrate is virtually eliminated thus reducing a potentially catastrophic failure from occurring. ES3 expects the following benefits from the prototyping and verification of the Versagrind Belt Finishing machines: That validation of optimized belts and process variables do not create burns on 300M or 4340 substrates. That the requirements and equipment for a scaled-up production systems will be identified. All significant production issues will be identified Safety considerations and equipment requirements will be identified Success of this installation will enable commercial landing gear OEM"s and other DoD installations to implement the technology using proven methods

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

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