N141-045 TITLE: Rapid Computer Numerical Control (CNC) Tool-path Programming

TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: PMS397, OHIO Replacement Program (ACAT 1).

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted". The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: The objective of rapid CNC tool-path machining is to develop a new capability to enable shorter, more efficient manufacturing processes for large scale, high tolerance Navy Hardware.

DESCRIPTION: Currently the manufacturing for Large Scale Vehicle (LSV) and Navy submarine propulsors requires casting nickel aluminum bronze (NAB) and then machining the castings into their final shape. These hydro shapes have high tolerance requirements on them, in order to ensure performance. A large part of this manufacturing process is the manual programming of the tool-paths for the CNC machines (ref 1,2)

As it currently stands, CNC programming for the NAVY requires special training and manual programming of machine paths. This can be the longestand most expensive part of the machining process. It can cause an increase in manufacturing times, result in costly hardware, as well as delay delivery of critical components.

An innovative solution is needed for the creation of a rapid CNC tool-path program, through some level of automation (ref 3,4) Proposed CNC tool-path programming shall meet the following goals: a reduction of 20% or better in programming time, maintain high tolerance requirements that are in place today, and reduce overall cost for CNC programming.

PHASE I: The small business will develop a concept for an improved CNC tool-path program that meets the requirements described above. The small business will demonstrate the feasibility of the concept in meeting Navy needs and will establish that the concept can be feasibly developed into a useful product/process for the Navy. Feasibility will be established by material testing and analytical modeling. The small business will provide a Phase II development plan that addresses technical risk reduction and provides performance goals and key technical milestones.

PHASE II: Based on the results of Phase I and the Phase II development plan, the small business will develop a prototype for evaluation. The prototype will be evaluated to determine its capability in meeting the performance goals defined in Phase II development plan and the Navy requirements for the rapid CNC tool-path program. System performance will be demonstrated through prototype evaluation and modeling or analytical methods over the required range of parameters including numerous deployment cycles. Evaluation results will be used to refine the prototype into an initial design that will meet Navy requirements. The small business will prepare a Phase III development plan to transition the technology to Navy use.

PHASE III: The small business will be expected to support the Navy in transitioning the technology for Navy use. The small business will develop a CNC tool-path program according to the Phase III development plan for evaluation to determine its effectiveness in an operationally relevant environment. The small business will support the Navy for test and validation to certify and qualify the system for Navy use.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: There are a number of private industries that could potentially benefit from the development of this technology. Notably, machining of water jet impellers requires high tolerance machining of high strength materials. The commercial maritime industry would be able to implement this technology. Another potential application would be in the machining of turbines that are used in high temperature/high stress applications. Reference the "Inner Hub Forging Procurement Specification" to apply the 20% improvement in processing times.

REFERENCES:
1. Smid, Peter. "CNC Programming Techniques-An Insider's Guide to Effective Methods and Applications." Industrial Press Inc., New York, NY. 2006. Library of Congress Cataloging. 28 February 2013 <http:// new.industrialpress.com/ext/pdfs/bookPDFs/CNCPT.Sample.pdf>.

2. Kim, Taejung. "Time-optimal CNC Tool Paths : A Mathematical Model of Machining." Massachusetts Institute of Technology, 2001. 04 Mar. 2013 <http://dspace.mit.edu/handle/1721.1/8861>.

3. Balic, Joze. "Intelligent CAD/CAM Systems for CNC Programming - An Overview." Advances in Production Engineering & Management Journal. 2006. University of Maribor, Faculty of Mechanical Engineering. 04 March 2013 <http:// http://pdf.aminer.org/000/355/431/a_model_for_the_organization_level_of_intelligent_machines.pdf>.

4. Dickin, Peter. "Feature-Based CNC Programming Cuts Programming Time by 25 to 75 Percent." Gardner Publications, Inc. 2009. MOLDMAKING TECHNOLOGY Magazine, Mar. 2009. 04 Mar. 2013 <http://www.yepedia.com/books/delcam-powermill.html>.

KEYWORDS: Computer Numerical Control (CNC); Manual Programming; Manufacturing process; Tool-path; large scale components

** TOPIC AUTHOR (TPOC) **

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