Dr. Matthew Davies is a mechanical engineer at the National Institute for Standards and Technology (NIST), where he leads several high–speed machining projects. Aerospace machine and parts manufacturers can learn new ideas and new processes from the military manufacturing projects in which NIST is involved.

Over the years, NIST has helped lay the foundation for prosperity and technological advancement in the United States. NIST research has been used to improve military machining techniques, and private manufacturers have much to learn from their findings as well. In 1989, NIST founded the Manufacturing Extension Partnership (MEP) in an effort to offer technical assistance and the latest business practices to the nation's smaller manufacturers. Today, manufacturers and machine shops in the aerospace industry have a lot to learn from NIST's research in high-speed machining.

As NIST continues its research in high-speed machining, military and private sector manufacturers alike will continue to learn from their invaluable developments, such as laser sintering. Laser sintering is the process that heats powder into layered shapes for prototype development, driven by CAD/CAM technology.

Cross-military high-speed machining techniques that are applicable to aerospace manufacturing primarily involve 6AL-4V titanium machining, according to Matthew Davies. His team has also been exploring new aerospace manufacturing processes, including combinations of near-net-shaped processes like laser sintering. The benefits of laser sintering are a more efficient use of material and a reduction in tool wear in high-speed machining applications.

For the small shop interested in high-speed machining, it can simply be a matter of retraining for many machinists used to the methods of conventional machining. The first instinct of many machinists when faced with chatter problems, for instance, is to turn down the spindle speed. But Davies warns that this isn't always the best approach. "When you deal with chatter problems by turning down the spindle speed, you end up using your machines at only 25 percent capacity."

The NIST continues to pursue machining developments for the military and beyond. "One big project NIST has been working on for the past three years with the U.S. Navy is the Naval Foundry and Propeller Center in Philadelphia," says Davies.

The Naval Foundry and Propeller Center is responsible for the manufacture of propulsion system components for ships and submarines, in which castings of up to 110,000 pounds are machined down to about 80,000 pounds with five-axis machine tools. The center is currently facing slow manufacturing due to outdated processes, something NIST is working hard to help them correct. "The Navy wants to transition the Naval Foundry and Propeller Center to high-speed machining and we are going to assist them."

For additional information about NIST, the National Institute of Standards and Research, contact them by phone at 301-975 NIST (6478). Or, visit their Website at www.nist.gov.

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