Aluminum accessory gearbox housings for aerospace applications are loaded into a CNC mill, constrained in a clamping fixture secured at multiple locations, then machined. After releasing the clamps, housings warp as a result of a buildup of residual stress which can lead to significant costs in the form of rework and scrap. Predicting the magnitude and direction of movement prior to machining will allow Aero Gear to build in compensation and lead to better clamping, cutting tool selection, and CNC programming practices (feeds/speeds/etc.). The goal is to perform finite element simulations and develop surrogate models to understand distortions and residual stresses to optimize for better clamping, cutting tool selection, and CNC programming practices.

A creative collaboration with ZANEEZ® Health in Glastonbury, Conn., is focusing on virtual prototyping of an innovative foot and ankle platform (i.e. Anklestone) made from advanced thermoplastic polymers. This process reduces the time and cost associated with multiple rounds of physical testing, optimizing structural integrity and product performance before physical production begins.