Past Projects

High Productivity Composite Machining

Optimized Composites

Through a series of progressively advancing composite machining programs for the F135 and demonstrated gains in efficiency and improved quality by applying its physics-based modeling technology and optimizing current F135 machining processes. Machining time was reduced by nearly 50 percent, while quality was improved to a point where the demonstration component passed First Article Inspection. This was achieved by modeling the machining of polymer matrix composites (PMCs) and to predict and optimize forces and temperatures during machining as well as control them through feed and speed selection.

Gear Hobbing Predictive Model

Gear Machining

  • The project focused on demonstrating the feasibility of innovative physics-based modeling of gear hobbing to predict and improve residual stresses, and heat treat distortions while reducing production cycle times and costs of transmission gears.
  • The first version is focused on the cylindrical hobbing process enabling users to study this metal cutting process in a virtual environment. This software will help users to reduce manufacturing costs through improvements in tool life and process parameter optimization, improve gear quality by predicting chip formation problems and the effect of process changes on the machining induced heat and stress and increase development ROI by reducing iteration time and trial-and-error testing.

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