Manufacturing Methods for High Speed Machining of Aluminum

The objective of this program was to develop manufacturing methods and technology for machining aluminum at significantly higher speeds than is currently practiced. Additionally, the methodology developed was to be satisfactorily demonstrated as being both practical and cost-effective when compared with current machining practices. To accomplish these objectives, a three-phase program was conducted. In Phase I, cutting tools and machining parameters were tested for the purpose of making machining recommendations for selected aluminum alloys. Expanded machining data e.g., tolerances, finishes, deflection, cutting forces, horsepower, residual stresses and cutting temperature were also developed to ascertain the effects of high speed machining on product integrity. In Phase II, Guidance and Control Shells for the Lance missile were machined, in part, with the new methods to establish cost data for comparison with present methods. Also, performance data for the methods were analyzed and interrelationships were developed among pertinent machining properties and variables. In Phase III, new high-speed machining methodologies developed in the program were demonstrated to representatives of the Government and the aluminium fabricating industry.