T. Marusich, Third Wave Systems, Minneapolis, MN
Machined monolithic aircraft components–components machined from one solid plate or forged structure–are the foundation for improved performance, and cost and part count reduction in the airframe industry. Components machined from plate are pervasive throughout the aircraft industry and commonly have start-to-finish machining weight ratios of 20:1 to 50:1, resulting in complicated CNC toolpaths and long cycle times. Migration to new and more advanced alloys to provide performance benefits is often at the expense of manufacturing time and cost. An emerging opportunity exists to dramatically improve CNC metal machining via physics-based optimization of both new and existing CNC part programs. Physic-based modeling allows detailed analysis of cutting tool/workpiece interaction for improved cutter design and thermal management of titanium and high temperature alloys. Physics-based modeling also allows analysis of forces, temperatures and tool stresses over entire part programs, quickly identifying opportunities for cycle time reduction and potential areas of part damage. In this paper, an approach for physics-based modeling of both detailed tool/workpiece interaction and CNC toolpath analysis will be detailed. An overview of modeling capabilities will be shown along with application to typical aerospace components.
Summary: Physics-based modeling of machining processes is applied to aerospace components to predict forces and temperatures. These data are used to modify the machining process cutting speed and feed rates for cycle time reduction and improved part quality.
