Grant: Collaborative Research and Development Grants

The use of composite materials is increasing rapidly in the aeronautical and aerospace industry. Their specific strength and stiffness, as well as their relative light weight compared to metallic alloys convey them a net advantage for the production of lighter aircrafts. Even though composite components are produced to near-net-shape, additionalmachining operations are often required for assembly purposes. The most frequent machining operations are drilling holes for screws, bolts or rivets, as well as trimming openings or edges according to specific sizes and ·geometric tolerances. Unlike metallic materials, composite materials raise some specific problems during machining. Fibers used as reinforcement cause fast abrasive tool wear and their delamination deteriorates the machined surfaces. Damages such as delaminating, cracks or matrix thermal degradation are also observed as the result of tool wear or improper machining conditions. These quality problems, which severely affect the mechanical properties ofparts, are the cause of an important rejection rate of machined composites parts. The assessment of proper cutting methodologies and machining conditions for the production of composite components thus becomes a necessity for the Canadiari aeronautical industry to produce greener aircrafts at a lower cost in a very competitive global market. The project will focus on advanced cutting tools development as well as the optimization ofmachining conditions for the· drilling, trimming and five axis machining of CFRP and multilayer materials. Innovative models, algortihms, methodologies and cutting data bases will be developed as outcome ofthis project which involve as partners Bombardier aerospace, Avior Integrated Prociucts, Delastek, Minicut International, AV&R Vision&Robotics, Ecole de Technologie Superieure, Ecole Polytechnique de Montreal, Universite du Quebec aTrois-:-Rivieres and Centre Technologique en Aerospatiale.