Outline
• NRC IAR-AMTC Profiles
• Areas of Common Interest in Machining: Modeling and simulation of the machining process.
Process optimization based on selection of machining strategy.
High performance superabrasive grinding technology,
Laser assisted machining of difficult-to-cut materials,
Sustainable Manufacturing; Near Dry Machining or Minimum
Quantity Lubrication (MQL),
Dynamics modeling for machining thin structures.
NRC-AEROSPACE MANUFACTURING
Institute for Aerospace
Research (IAR)
IAR PROFILE
The main centre for aerospace research in
Canada
• 350 employees (100 guest workers)
• $30-35M budget ($20M income)
• 2 Ottawa sites, 1 Montreal site
Five Laboratories
• Aerodynamics (AL)
• Structures & Materials
Performance (SMPL)
• Flight Research (FRL)
• Gas Turbine (GTL)
• Manufacturing (AMTC)
NRC-AEROSPACE MANUFACTURING
AMTC R&D Program Scope
Four Technology Thrusts :
• Material removal technologies.
• Forming and joining of metallic products.
• Automation, robotics and IMS.
• Forming and joining of composite products
NRC-AEROSPACE MANUFACTURING
1. Machining/ Drilling of Composites and MMC
1. Process Development and Optimization; VAM, orbital
drilling (S/A tools), and MQL technologies.
2. Defect characterization and effect of defects
(testing/modeling of mechanical performance).
3. Process modeling.
2. Grinding/Polishing Processes
1. HP/Superabrasive Grinding; processes development for
5X grinding.
2. Process modeling and simulation (virtual grinding).
3. Machinability Enhancement, SustainableManufacturing and Tool Life Management
1. Machinability of aerospace materials.
2. Laser assisted machining.
3. Minimum Quantity Lubrication (MQL).
FY
FZFX
NRC Material Removal R&TD Program
NRC-AEROSPACE MANUFACTURING
4. Physics-based Modeling / Simulation of the Machining System 1. Identification of materials constitutive laws in
machining; metals/ composites, MMC.
2. Dynamics of Tool-WP-Fixture System.
3. Simulation of the machining process; distortion,
residual stresses, burr formation.
5. Process Optimization and Control
1. Adaptive control / optimization of machining
processes for composite/metallic components.
2. Process monitoring for Closed Machining System.
3. Compensation of thermal errors in machine tools/
workpiece and CMM structures.
NRC Material Removal R&TD Program
NRC-AEROSPACE MANUFACTURING
-3
-2
-1
0
1
2
3
0 500 1000
Resid
ual e
rro
rs, m
m
Time, s
• Develop a methodology for material
characterization at high (t, e, e, T)..
Physics-Based Modeling
and Simulation
Laser
Head
IR
Camera
Workpiece
Cutting
Tool
Dynamometer
Laser preheated cutting tests
Slip
Ring
NRC-AEROSPACE MANUFACTURING
Model Fc
(N/mm)
tc
(mm)
lc
(mm)
Proposed 10% 40% 20%
S-O-T-A 350% 200% 80%
• Process simulation and
optimization (residual
stresses, distortion, burr
formation, microstructure
evolution, …).
Physics-Based Modeling
and Simulation
NRC-AEROSPACE MANUFACTURING
Model Fc
(N/mm)
tc
(mm)
lc
(mm)
Proposed 10% 40% 20%
S-O-T-A 350% 200% 80%
• Process simulation and
optimization (residual
stresses, distortion, burr
formation, microstructure
evolution, …).
0.99
Martensite
Volume Fraction-Martensite0.99
0.66
0.33
0.00
MartensiteMartensite+
Ferrite
Ferrite +
Pearlite
Physics-Based Modeling
and Simulation
NRC-AEROSPACE MANUFACTURING
Evaluation of different strategies for pocket-milling of Beta-
Titanium Ti-10V-2Fe-3Al. The assessment was made base
on the following criteria:
• Cutting forces.
• Power consumption.
• Tool wear.
• Form accuracy.
• Dimensional accuracy.
• Surface finish.
• Machining Time.
Machining Strategies
Process Optimization based on Selection of Machining Strategy
NRC-AEROSPACE MANUFACTURING
Strategies and Cutting Conditions:
Three combinations of cutting operations including helical milling, drilling,
plunging, slotting, end and side milling.
Cutting Tools:Solid and indexable-insert endmills, drills, and plungers.
Tool diameters between 16 and 32 mm.
Cutting Speed:Up to 120 m/min (394 sfm).
Feed/Tooth:Up to 0.2 mm (0.008”)
Radial Immersion:Up to 32 mm (11/4” )
Depth of Cut:Up to 39.8 mm (1.567”)
Process Optimization based on Selection of Machining Strategy
NRC-AEROSPACE MANUFACTURING
Machining Strategies: Summary
Po
cket
Cu
tting
Tim
e
Pocket Quality
To
ol
Wear
Fin
ish
Ap
peara
nce
Fo
rm
Accu
rac
y
Dim
en
sio
nal
Accu
rac
y
Su
rface
Ro
ug
hn
ess
Recta
ng
ula
r
SII SIII SIII SIII SIII SI
SI SII SII SII
SI & SII
SII
SIII SI SI SI SIII
Tria
ng
ula
r
SI SIII SII SII SIII SI
SIII SII SII SIII SII SIII
SII SI SI SI SI SII
Rating: Best: Green 2nd Best: Blue Third: Red
Process Optimization based on Selection of Machining Strategy
NRC-AEROSPACE MANUFACTURING
Objective:
Modeling of high speed deep grinding
of steels, nodular C.I. AND Ni-alloys
Process optimization to achieve
maximum material removal rates.
Challenges:
Usage of high wheel speeds (up to
75,000 rpm).
Perform OD grinding on machining
centers with multiple functionality and
control systems.
Workpiece materials, e.g., superalloys,
and nodular cast iron which is very
sensitive to thermal damage and
cracking.
High Performance Superabrasive Grinding
Experimental setup
Workpiece
Wheel dresser
Sensor
AE sensor (uniformity
of dressing in axial)
Vibration
DynamicBalancer
NRC-AEROSPACE MANUFACTURING
Prediction of Grinding Force Distribution in the
Contact Zone
• For process Optimization: Prediction of temperature
distribution, thermal damage, surface finish, part
dimension, wheel life, surface integrity, cycle times etc.
• Analytical solution.
• Experimental; a novel technique.
• 3D-Numerical solution; multi grain case with random
grain height and spatial distributions. Horizontal Cutting Force
Time,s
0 10 20 30 40 50 60 70
Forc
e, N
-40
-30
-20
-10
0
10
20
Total Force
Coolant Force
Cutting Force
Vertical Cutting Force
Time,s
0 10 20 30 40 50 60 70
Fo
rce
, N
-40
-20
0
20
40
60
80
100
120
140
160
Total Force
Coolant Force
Cutting Force
CBN
High Performance Superabrasive Grinding
NRC-AEROSPACE MANUFACTURING
Laser Assisted Machining of Inconel 718
170
130
11095 90
140
7565 60 55
240
180165
160 160
0
50
100
150
200
250
300
Conventional 100
Laser - 100 Laser - 150 Laser - 200 Laser - 250
Fo
rce
(N
)
V, m/min
Cutting Forces
Feed Forces
Radial Forces
1.46
0.280.42
0.26
0.53
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
1.80
2.00
100 Conv. 100 LAM 150 LAM 200 LAM 250 LAM
Ra
(μ
m)
V, m/min
Experimental setup
of Laser Assisted
Machining
Laser assisted Machining of Difficult-to-Cut Materials
Surface Smearing
63 μm
Smearing
Conventional
127 μm
LAM
SEM image of
failed ceramic tool
at 300 m/min and
0.4 mm/rev under
(a) conventional,
(b) LAM.
Adhesion
Rake Face Rake Face
Flank
FaceFlank
Face200 mm200 mm(a)
Abrasion
(b)
NRC-AEROSPACE MANUFACTURING
NEAR DRY MACHINING (NDM) /
MINUMUN QUANTITY LUBRICATION (MQL)
Motivation
Substitution of to dry and wet cutting due to
its impact on the economy (cost reduction
by 20-35 %) [CIRP, EU FP-5 Program] and the
environment (50% reduction of power
consumption and 60% reduction in waste
disposal volumes).
Description
Effect of MQL on machining performance in
turning, drilling and milling of Al 6061, 300M
high strength steel, and CFRP composites,
compared to dry and wet cutting.MQL Application Unit Setup
Calibrated oil
flow meter
Sustainable Manufacturing:Near Dry Machining/MQL
NRC-AEROSPACE MANUFACTURING
MQL Milling Applications Al 6061
IR camera
MQL nozzle
Cutter
Force
Transducer
MQL
Al adhesion
on the tool
Broken
edge
Dry, broken (4,000 rpm)Surface damage
Alumium adhering to the workpiece
0
100
200
300
400
0 5 10 15
Tem
pera
ture
(°C
)
Time (s)
MQL
Dry
Minimum Quantity Lubrication (MQL): (4,000 rpm, 0.15 mm/tooth, 5 mm depth of cut, 9 ml/hr)
NRC-AEROSPACE MANUFACTURING
Sustainable Manufacturing:Near Dry Machining/MQL
0
100
200
300
400
0 400 800 1200 1600
Length of cut, mm
Nose r
adiu
s w
ear,
mm
Dry
Flood
MQL
Turning Applications0
0.4
0.8
1.2
0 100 200 300Nose Radius Wear, mm
Roughne
ss R
a,
mm
Dry
Flood
MQL
M300 Steel (400 m/min)
Dry
Flood
MQL
Development of model for the dynamics of thin-walled structures:
The continuous change of thickness. Effect of the constraints imposed by the fixture. Prediction errors < 10%. Computationally efficiency: One order of
magnitude improvement. Numerically and experimentally validation.
Locator/
support
Edge
clamp
Custom clamp
WorkpieceSide 1
Side 2
Side 3
Side 4
Span 1Span 2
Span 3Span 4
NRC-AEROSPACE MANUFACTURING
Machining Dynamics of
Thin Structures
Development of model for the dynamics of thin-walled structures:
The continuous change of thickness. Effect of the constraints imposed by the fixture. Prediction errors < 10%. Computationally efficiency: One order of
magnitude improvement. Numerically and experimentally validation.
Locator/
support
Edge
clamp
Custom clamp
WorkpieceSide 1
Side 2
Side 3
Side 4
Span 1Span 2
Span 3Span 4
NRC-AEROSPACE MANUFACTURING
Machining Dynamics of
Thin Structures
Development of a data-base for the stability lobes of tool/tool holder systems and application to the optimization of the milling process of complex parts.
Part Tool
Effect of Wp2 and US-FAM063-0028
dynamics in down milling rdoc =12.6 mm,
orientation = 0 Degrees
0
4
8
12
16
20
0 500 1000 1500 2000 2500(rpm)
ax
ial d
ep
th o
f c
ut
(mm
)
tool dynamics Wp2 dynamics
Wp2 and tool dynamics upper limit of doc
Machining Dynamics of
Thin Structures
Effect of tool length on stability lobes.
US-FAM063-0027 and -0028 tools, rdoc =12.6 mm,
orientation = 0 Degrees
0
2
4
6
8
0 500 1000 1500 2000 2500
(rpm)
ax
ial
de
pth
of
cu
t
(mm
)
Tool length 175 mm Tool length 265 mm
Uper limit of doc
US-FAM063-0028, rdoc=12.6 mm, D=63mm
0.5
1.0
1.5
2.0
2.5
500 1000 1500 2000(rpm)
ad
oc
(m
m)
0 Deg 30 Deg 60 Deg
90 Deg Enveloppe adoc-limit
Other Areas of
Common Interest
• Robotized welding processes
• Processes development for injection molding that offer equivalent
mechanical properties of compression molded plastic composites
(IMI)).
• Material development for injection molding reinforced by glass
fibre (IMI).
• Precision machining of large complex and large components; jet
engine components, fan frames, duct fan fronts, compressors
frames, etc.
• BTA deep hole drilling/ Gundrilling.
• Precision sheet metal processing.
• In-situ repair of machine tools spindles (inner surface taper
correction).
NRC-AEROSPACE MANUFACTURING
• Hydroforming.
• Remote laser welding systems.
• Friction stir welding.
• Robotized systems (HS vision platform).
• Hard coatings (CVD, PVD).
• Manufacturing sensors technology, for measurement and control
purposes.
NRC-AEROSPACE MANUFACTURING
Other Areas of
Common Interest
Thank you! Questions?
See also: NRCaerospace.com