Multi-Operation Process Optimization

Using Quantized Relational Reality (QRR) Field Analysis

Turn Physics into Profit for High-Value Aerospace Components

$322,514 Annual Savings on 150 Parts

Ti-6Al-4V Landing Gear Components

1/10

The Problem

Conventional machining treats each operation independently

Critical Issues Overlooked:

  • Work hardening persists from one operation to the next
  • Residual stress accumulates and causes distortion
  • Thermal damage compromises downstream operations
  • Aggressive roughing destroys finishing capability

Ti-6Al-4V can work harden 30-50%

From 33 HRC → 45 HRC after aggressive cutting

2/10

The Impact

For difficult materials like Ti-6Al-4V titanium:

Tool Life Reduction
3-5×
Faster wear on hardened surfaces
Forging Cost
$8,500
18-week lead time
Critical Tolerance
±0.0005"
On bearing bores (12.7 microns)
Scrap Impact
Catastrophic
One lost part = major loss

Conventional planning "saves" hours in Op10... then loses the part in Op40

3/10

The QRR Solution

Multi-operation field modeling optimizes the ENTIRE process

Key Physics Modeled:

  • Work hardening accumulation across operations
  • Tool life degradation on hardened surfaces
  • Tolerance capability and dimensional stability
  • Thermal effects in low-conductivity materials

The Strategy

Accept slower roughing to enable faster, more reliable downstream operations

"What Op10 parameters create the optimal state for Op20, Op30, and Op40 to succeed?"

4/10

Case Study Results

Ti-6Al-4V Landing Gear Torsion Link

Metric Conventional QRR-Optimized Improvement
Cost per Part $12,828 $10,478 -$2,150 (17%)
Op40 Failure Risk 15.4% 12.1% -3.3 points
Surface Hardness (Op40) 45.2 HRC 41.8 HRC -3.4 HRC
Annual Savings (150 parts) — — $322,514
ROI: 4:1 — Spend $540 in extra Op10 time, save $2,150 total per part
5/10

Where the Savings Come From

Tool Cost Reduction
$2,569

Better tool life from optimized parameters across all operations

Scrap Risk Reduction
$328

Improved Op40 tolerance capability on $8,500 forgings

Machine Time Trade-off
-$540

Op10 takes 4 extra hours at $150/hr shop rate

Net Savings
$2,150

17% cost reduction per part

The "extra" machine time is MORE than offset by tool and scrap savings

6/10

Why Op40 is Critical

Bearing bore tolerance: ±0.0005" (12.7 microns)

Conventional Strategy

Surface entering Op40: 45.2 HRC

  • Reamer wears rapidly (3-5 bores)
  • Chatter risk increases
  • Cannot reliably hold tolerance
  • 15.4% failure risk

QRR-Optimized Strategy

Surface entering Op40: 41.8 HRC

  • Reamer life extends (30-35 bores)
  • Stable cutting conditions
  • Tolerance capability maintained
  • 12.1% failure risk

The 3.4 HRC difference makes or breaks this operation

7/10

When Does This Work?

Ideal Candidate Parts:

  • Difficult Materials: Titanium alloys, Inconel, hardened steels
  • Multi-Operation: 3+ operations with state propagation
  • High Stakes: Expensive forgings ($5,000+), long lead times
  • Tight Tolerances: ±0.001" or tighter on critical features
  • Current Pain: "We nail Op10-20, then fail in Op30-40"

Not Ideal For:

  • High-volume, simple parts
  • Soft, easy-to-machine materials (aluminum 6061, mild steel)
  • Single or 2-operation processes
8/10

How We Work With You

1

Analysis

1-2 weeks

  • Multi-operation field analysis
  • Critical coupling points
  • Predicted savings
  • Process recommendations
2

Validation

2-4 weeks

  • Test parts with optimized parameters
  • Measure actual results
  • Refine predictions
  • Validate cost savings
3

Implementation

Ongoing

  • Process documentation
  • Operator training
  • Monitoring & adjustment
  • Additional parts

Our Philosophy: We only make money if you make money

Success fee based on demonstrated savings

9/10

Is This Relevant to Your Shop?

Questions to Ask Yourself:

  • Do we machine titanium, Inconel, or other difficult materials?
  • Do we have parts with 3+ operations where later ops are problematic?
  • Are we experiencing unpredictable scrap/rework on tight-tolerance features?
  • Do finishing operations struggle with surfaces from aggressive roughing?
  • Would saving $2,000-5,000 per part be meaningful to our business?

If you answered "yes" to 3+ questions, let's talk.

No charge • Problem part assessment • ROI estimate

10/10