U.S. patent application number 14/048174 was filed with the patent office on 2014-02-13 for system and method for adaptive machining.
This patent application is currently assigned to General Electric Company. The applicant listed for this patent is General Electric Company. Invention is credited to Michelle Rene Bezdecny, Michael Evans Graham, Timothy Mark Heitzman, Arvind Rangarajan.
Application Number | 20140041183 14/048174 |
Document ID | / |
Family ID | 40197247 |
Filed Date | 2014-02-13 |
United States Patent
Application |
20140041183 |
Kind Code |
A1 |
Rangarajan; Arvind ; et
al. |
February 13, 2014 |
SYSTEM AND METHOD FOR ADAPTIVE MACHINING
Abstract
A method of repair includes removing a deformed portion of a
component to define a native component portion and adding a
replacement portion to the native component portion. The
replacement portion is adaptively machined based on one or more
parameters of the native component portion and based on one or more
original design parameters of the component.
Inventors: |
Rangarajan; Arvind; (Santa
Clara, CA) ; Graham; Michael Evans; (Slingerslands,
NY) ; Bezdecny; Michelle Rene; (Centreville, VA)
; Heitzman; Timothy Mark; (Mainville, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Assignee: |
General Electric Company
Schenectady
NY
|
Family ID: |
40197247 |
Appl. No.: |
14/048174 |
Filed: |
October 8, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11954178 |
Dec 11, 2007 |
8578579 |
|
|
14048174 |
|
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Current U.S.
Class: |
29/402.09 |
Current CPC
Class: |
G05B 2219/45147
20130101; G05B 19/4083 20130101; Y02T 50/60 20130101; G05B
2219/50214 20130101; Y10T 29/49718 20150115; B23P 6/007 20130101;
G05B 19/4097 20130101; F01D 5/005 20130101; Y10T 29/49318 20150115;
G05B 2219/49066 20130101; Y10T 29/49732 20150115; G05B 2219/35097
20130101; G05B 2219/35031 20130101; Y02T 50/673 20130101 |
Class at
Publication: |
29/402.09 |
International
Class: |
F01D 5/00 20060101
F01D005/00; B23P 6/00 20060101 B23P006/00 |
Claims
1. A computer-implemented method, comprising: receiving actual
measurements of a component having an undesirable portion, wherein
the undesirable portion comprises a deformation, a damaged portion,
an undesirable shape, or a combination thereof; and transforming a
computer model of the component based on the actual measurements
and an original design intent, a new optimized design, or a
combination thereof.
2. The computer-implemented method of claim 1, comprising
identifying deviation between the actual measurements and points in
the computer model.
3. The computer-implemented method of claim 1, comprising
identifying a rigid patch and a warp patch on the component based
on deviation between actual measurements and the computer
model.
4. The computer-implemented method of claim 1, comprising
registering the computer model to a rigid patch of actual
measurements on the component.
5. The computer-implemented method of claim 4, wherein registering
comprises creating a rigid body transformation of the computer
model at least generally geometrically matched with actual
measurements exhibiting low deviation relative to the computer
model.
6. The computer-implemented method of claim 4, comprising
transforming the computer model in a warp patch of actual
measurements on the component.
7. The computer-implemented method of claim 6, wherein transforming
the computer model in the warp patch comprises creating a set of
virtual points that are adjustable to achieve the original design
intent, the new optimized design, or a combination thereof.
8. The computer-implemented method of claim 6, comprising
outputting instructions for a machine to shape the component at
least in the undesired portion according to the original design
intent, the new optimized design, or the combination thereof.
9. The computer-implemented method of claim 8, comprising executing
the instructions on the machine.
10. A method of operating an adaptive machining system for
machining a component having a native component portion,
comprising: measuring a first set of points on the native component
portion; determining an initial position of a computer model of the
component by rigid body transformation using the first set of
points measured on the native component portion to form a
transformed computer model; creating a second set of points on the
transformed computer model; wherein the second set of points on the
transformed computer model corresponds with the first set of points
on the native component portion; and morphing the transformed
computer model by matching the first set of points with the second
set of points.
11. The method of claim 10, wherein measuring the first set of
points on the native component portion comprises dividing the
native component portion into a rigid patch and a warp patch.
12. The method of claim 11, wherein determining the initial
position of the computer model of the component comprises
registering the computer model to the rigid patch.
13. A method of operating an adaptive machining system for
machining a component having a native component portion,
comprising: creating a set of points in a built-up region of a
transformed computer model representative of the native component
portion; and applying a rigid body transformation and morphing to a
plurality nominal cutter contact points of a nominal tool path so
as to match the nominal cutter contact points with the set of
points to form a plurality of deformed cutter contact points;
wherein the plurality of deformed cutter contact points form a
deformed tool path.
14. The method of claim 13, comprising removing a deformed portion
of the component to form the native component portion.
15. The method of claim 14, further comprising replacing the
deformed portion using a replacement portion by joining the
replacement portion to the native component portion.
16. The method of claim 15, wherein the built-up region of the
transformed model corresponds with replacement portion.
17. The method of claim 13, wherein morphing the plurality of
nominal cutter contact points of the nominal tool path comprises
overlapping the nominal cutter contact points with the set of
points to form the plurality of deformed cutter contact points of
the deformed tool path.
18. The method of claim 13, wherein morphing the plurality of
nominal cutter contact points of the nominal tool path comprises
offsetting the nominal cutter contact points from the set of points
to form the plurality of deformed cutter contact points of the
deformed tool path.
19. A computer program to enable a controller operating an adaptive
machining system for machining a component having a native
component portion, the computer program comprising: programming
instructions stored in a tangible medium that enable the controller
to receive actual measurements of a component having an undesirable
portion, wherein the undesirable portion comprises a deformation, a
damaged portion, an undesirable shape, or a combination thereof;
and programming instructions stored in a tangible medium that
enable the controller to transforming a computer model of the
component based on the actual measurements and an original design
intent, a new optimized design, or a combination thereof.
Description
BACKGROUND
[0001] The disclosure relates generally to machining, and more
particularly to a system and method for adaptive machining of
components such as airfoils.
[0002] In many applications, such as aircraft, various parts are
built with a particular shape or contour, for example, for
aerodynamics. Through normal service, there arises a need to repair
components such as airfoils in aircraft applications, for example.
With respect to airfoils, damage to a leading edge of the airfoil
is one of the most common problems. The leading edge is subject to
foreign object damage or erosion after a period of service time. A
significant savings can be realized if the damaged blades can be
repaired and returned to service.
[0003] Conventionally, the repair has been accomplished by
machining away the damaged portion of the airfoils. Welding
material was then manually deposited over the areas that had been
machined away. The component was then machined by referencing a
nominal model geometry in an attempt to reproduce the originally
designed dimensions. Then, the component was hand finished,
manually machined, in order to put the component in a serviceable
condition.
[0004] However, there are shortcomings associated with the
historical repair method. The method requires leaving a significant
amount of material remaining (i.e., stock on) after the machining,
which must be removed by a hand finishing process. This is due to
the fact that no component, or blade within a component, is exactly
at a nominal condition. The manual nature of the hand finishing
process increases the cost and processing time of the repair.
Finally, the method results in significant scrap.
BRIEF DESCRIPTION
[0005] In accordance with one exemplary embodiment of the present
technique, a method of repair is disclosed. The method includes
removing a deformed portion of a component to define a native
component portion and adding a replacement portion to the native
component portion. The replacement portion is adaptively machined
based on one or more parameters of the native component portion and
based on one or more original design parameters of the
component.
[0006] In accordance with another exemplary embodiment of the
present technique, a computer-implemented method is disclosed. The
method includes receiving actual measurements of a component having
an undesirable portion. The undesirable portion includes a
deformation, a damaged portion, an undesirable shape, or a
combination thereof. A computer model of the component is
transformed based on the actual measurements and an original design
intent, a new optimized design, or a combination thereof.
[0007] In accordance with another exemplary embodiment of the
present technique, a method of operating an adaptive machining
system used for machining a component having a native component
portion is disclosed. The method includes measuring a first set of
points on the native component portion. An initial position of a
computer model of the component is determined by rigid body
transformation using the first set of points measured on the native
component portion to form a transformed computer model. A second
set of points is created on the transformed computer model. The
second set of points on the transformed computer model corresponds
with the first set of points on the native component portion. The
transformed computer model is morphed by matching the first set of
points with the second set of points.
[0008] In accordance with another exemplary embodiment of the
present technique, a method of operating an adaptive machining
system used for machining a component having a native component
portion is disclosed. The method includes creating a set of points
in a built-up region of a transformed computer model representative
of the native component portion. The method also includes applying
a rigid body transformation and morphing to a plurality nominal
cutter contact points of a nominal tool path so as to match the
nominal cutter contact points with the set of points to form a
plurality of deformed cutter contact points; wherein the plurality
of deformed cutter contact points form a deformed tool path.
[0009] In accordance with another exemplary embodiment of the
present technique, a computer program to enable a controller
operating an adaptive machining system for machining a component
having a native component portion is disclosed. The computer
program includes programming instructions stored in a tangible
medium that enable the controller to receive actual measurements of
a component having an undesirable portion. The undesirable portion
includes a deformation, a damaged portion, an undesirable shape, or
a combination thereof. The computer program also includes
programming instructions stored in a tangible medium that enable
the controller to transforming a computer model of the component
based on the actual measurements and an original design intent, a
new optimized design, or a combination thereof.
DRAWINGS
[0010] These and other features, aspects, and advantages of the
present disclosure will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0011] FIG. 1 is a diagrammatical representation of a system for
machining a component, for example an airfoil in accordance with an
exemplary embodiment of the present technique;
[0012] FIG. 2 is a diagrammatical representation of a component
surface having a warp patch and rigid patch in accordance with an
exemplary embodiment of the present technique;
[0013] FIG. 3 is a diagrammatical representation of nominal cutter
contact points and morphed cutter contact points generated by an
adaptive machining system in accordance with an exemplary
embodiment of the present technique;
[0014] FIG. 4 is a diagrammatical representation of a flow chart
illustrating exemplary steps involved in adaptive machining in
accordance with an exemplary embodiment of the present
technique;
[0015] FIG. 5 is a diagrammatical representation of a flow chart
illustrating exemplary steps involved in adaptive machining used
for machining an airfoil in accordance with an exemplary embodiment
of the present technique.
DETAILED DESCRIPTION
[0016] As discussed in detail below, embodiments of the present
technique provide a method for repairing a component, for example,
an airfoil. The method includes removing a deformed portion of a
component to define a native component portion. A replacement
portion is added to the native component portion. The replacement
portion is adaptively machined based on one or more parameters of
the native component portion and also one or more original design
parameters of the component. Other embodiments include a
computer-implemented method, a tangible medium including
computer-readable or machine-readable code, and a method of
operating an adaptive machining system configured to repair a
component based on at least in part on an original design intent,
an optimum design, or a combination thereof, as well as present
measurements (e.g., dimensions) of the component undergoing repair.
In one embodiment, the exemplary technique is applicable to a
manufactured component having an undesirable shape, e.g. an airfoil
with a blunted leading edge.
[0017] The exemplary embodiments provide a technique for defining
and machining the final shape of a repaired part. The exemplary
technique employs a geometric model of the component. This model
may be a CAD model or geometry constructed from a library of
measurement data. In one embodiment, the model may be a mesh model.
The exemplary technique extrapolates information from measured
points on the component and computer model to obtain a smooth
"as-is" shape of the component. An initial position for the
computer model is determined using a rigid body transformation
computed using points measured on a surface of the native component
portion. This provides an initial preferred location and
orientation for shaping the newly added replacement portion. The
transformed model geometry is then deformed using a function or
process to smoothly blend the native component portion with the
replacement portion. Actual tool paths or other processing steps
are then derived from either the new geometry, or through the
application of the rigid body transformation and the deformation
process directly to nominal tool paths or process parameters. The
shape attributes for the replaced portion may be easily controlled
by the user, allowing optimization and customization of the
machining process. Specific embodiments of the present technique
are discussed below referring generally to FIGS. 1-5.
[0018] Referring to FIG. 1, an exemplary adaptive machining system
10 used for machining a component 12 such as, for example, an
airfoil of an aircraft engine, is illustrated in accordance with
certain embodiments of the present technique. The system 10
includes a measurement system 14 configured to provide a first set
of measurement points 16 on the component 12 having an undesirable
portion. The undesirable portion includes a deformation, a damaged
portion, an undesirable shape, or a combination thereof. It should
be noted herein that the measurement points 16 are in the "x, y, z"
coordinate system and is referred to as the "measured coordinate
system". The measurement system 14 may include but not limited to a
5-axis milling machine, coordinate measuring machine (CMM), an
x-ray scanning machine, an optical scanning machine, or an
ultrasound scanning machine. The system 10 also includes a computer
model 18 (e.g., CAD model) of the component. The computer model 18
of the component is representative of the component geometry,
shape, appearance, or a combination thereof, after undergoing a
particular machining operation. The computer model 18 includes a
second set of points in the "X, Y, Z" coordinate system and is
referred to as the "computer model coordinate system".
[0019] A computer 20 receives the first set of measurement points
16 and the computer model 18. The computer 20 is configured to
determine the deviation between the first set of measurement points
16 on the component 12 and the second set of points of the computer
model 18. The computer 20 classifies the first set of measurement
points 16 on the component as "rigid patch" and "warp patch". Warp
patch may be referred to as a region proximate to a repair zone of
the component and rigid patch may be referred to as region away
from the repair zone of the component. Rigid patch and warp patch
are explained in greater detail with reference to subsequent
figures below. The computer 20 generates a transformation model
that approximates the deformation of the measured component 12
relative to the rigid patch. The computer 20 may be a general
purpose computer such as a work station, a personal computer, or a
machine controller. The computer 20 includes a processor 22 and a
memory 24 including a random access memory (RAM), read only memory
(ROM) and/or other components. The computer also includes a monitor
26, a keyboard 28, and a mouse device 30. The computer 20 operates
under control of an operating system stored in the memory 24 to
present data such as the set of measurement points 16 and the
computer model 18 to an operator via the display screen of the
monitor 26 and to accept and process commands from the operator via
the keyboard 28 and the mouse device 30. The computer 20 generates
the transformation model using one or more computer programs or
applications (e.g., code or instructions) through a graphical user
interface. Set forth below is a more detailed discussion of how the
computer 20 generates the transformation model. A computer-readable
medium, e.g., one or more removable data storage devices 32 or a
fixed data storage device 34, store the operating system, software
applications, and other code configured to carry out the
embodiments discussed in detail below. The storage devices 32 and
34 may include removable media drives and/or removable storage
media, such as floppy discs, compact discs, digital video discs,
flash memory, USB pen drives, and so forth. The storage devices 32
and 34 also may include hard disk drives.
[0020] The system 10 also includes nominal tool paths 36 for
operating a particular tool for machining the component 12. After
generating the transformation model, the computer 20 modifies the
nominal tool paths 36 to the measured coordinate system of the
component 12 according to the transformation model. Set forth below
is also a more detailed discussion of how the computer 20 modifies
the nominal tool paths 36. The modification of the nominal tool
paths 28 results in deformed tool paths 38. A milling controller 40
uses the deformed tool paths 38 to process the component 12 by
single pass machining or multi-pass machining.
[0021] Referring to FIG. 2, this figure is a diagrammatical
representation of a component surface 42 of the component 12 having
a native portion 44 and a built-up portion 46 in accordance with an
exemplary embodiment of the present technique. In the illustrated
embodiment, the component 12 is an airfoil. The airfoil is used
only for illustration of the disclosed embodiments, which are not
limited to any particular type of component or application. The
exemplary technique is equally applicable for repair applications
of other suitable components.
[0022] Repairing service parts (such as airfoils) often includes
removing damaged sections of the part to produce a "native" part,
and then replacing the damaged sections with either weld build-up
or some other metallic substitute that may be machined away to
produce a repaired part by smoothly blending the native part with
the built-up part. Smooth blending of the repaired part includes
accounting for rigid body errors in the original native part's
shape or position, change in part geometry due to service, and any
local warping induced by heating the native material during build
up processes. The exemplary embodiments enable users to maintain or
approach design intent, or to optimize their design based upon the
shape of native (remaining) portion of the part before repair.
[0023] The measurement system 14 is used to measure a first set of
points 16 on the outer surface of the native portion 44 of the
component 12. The computer model 18 is registered to the measured
first set of points 16 on the native portion 44 of the component
12. It should be noted herein that image registration may be
referred to as a process of transforming different sets of data
into one coordinate system. Registration is required in order to be
able to compare or integrate the data obtained from different
measurements. The computer model 18 is subjected to rigid body
transformation and morphing according to the measured first set of
points 16. As known to those skilled in the art, rigid body
transformation may be referred to as a rigid body motion wherein an
object may be moved from one position to another without altering
the shape and size. Typical rigid body transformations involve
translation, rotation, and reflection. Morphing may be referred to
as a technique that changes (or morphs) one image into another
through a seamless transition. The registering, rigid body
transforming, and morphing are explained in greater detail with
reference to subsequent flow charts. In the illustrated embodiment,
the computer 20 initially determines the deviation between the
first set of measurement points 16 on the native component portion
44 and the second set of points of the computer model 18. A rigid
patch 48 and a warp patch 50 are identified based on the deviation
between the first set of points 16 on the native component portion
44 and the second set of points of the computer model 18. Points 52
in the region away from the built-up or heated zone 46 (points
taken in thicker areas of the part) are referred to as the rigid
patch 48. Points 54 proximate to the built-up region 46 (thinner
regions of the part) are referred to as the warp patch 50. The
rigid patch 48 provides an estimate of the shape change as well as
errors in positioning and orientation of the component 12. The warp
patch 50 may change shape significantly due to heat and service.
Defining relevant patches on the native component portion 44 and
manipulating the patches in a sequence, enables the present
technique to obtain a smooth shape and properly defined
features.
[0024] Referring to FIG. 3, this figure is a diagrammatical
representation of nominal cutter contact points 56 and morphed
cutter contact points 58 generated by the machining system in
accordance with an exemplary embodiment of the present technique.
In the illustrated embodiment, to define the final geometry to be
machined from the built-up region of the component 12, the computer
system 20 creates a set of virtual points in a built-up region 46
of the transformed computer model. The built-up region 46 of the
transformed model corresponds with the built-up or replacement
portion of the component 12. These virtual points may be
manipulated for purposes of matching original design intent or
creating new optimized shapes at the point of repair or
manufacture. The nominal tool path 36 is registered to the set of
virtual points on the transformed computer model. The nominal tool
path 36 is then subjected to rigid body transformation and morphing
according to the set of virtual points so as to match the nominal
cutter contact points 56 of the nominal tool path 36 with the set
of virtual points of the transformed computer model to form the
plurality of morphed or deformed cutter contact points 58. The
plurality of deformed cutter contact points 58 form a deformed tool
path. The registering, rigid body, transforming, and morphing are
explained in greater detail with reference to subsequent flow
charts. In some exemplary embodiments, the nominal cutter contact
points 56 may be offset from the set of virtual points of the
transformed computer model to form the deformed cutter points 58 of
the deformed tool path so as to matching design intent or creating
new optimized shapes at the point of repair or manufacture. In some
embodiments, the original design including geometry and/or
dimensions of the component 12 may be adjusted based on actual
measurements of the native component portion.
[0025] Referring to FIG. 4, this figure is a flow chart
illustrating one exemplary embodiment of steps involved in adaptive
machining In the illustrated embodiment, the measurement system 14
generates a first set of measurement points 16 on the native
component portion as represented by the step 60. The computer 20
receives the first set of measurement points 16 from the
measurement system 14 and the computer model 18 of the component.
The computer 20 then determines the deviation between the first set
of measurement points 16 on the native portion and the second set
of points of the computer model 18 as represented by the step 62.
The computer 20 classifies the first set of measurement points 16
on the component 12 into rigid patch 48 and warp patch 50 as
represented by the step 64. The rigid patch 48 and warp patch 50
are identified based on the deviation between the first set of
points 16 on the native portion and the second set of points of the
computer model 18.
[0026] The computer model 18 is then registered to the first set of
measurement points 16. The computer model 18 is subjected to rigid
body transformation and morphing according to the rigid patch 48 as
represented by the step 66. The method further includes creating a
set of corresponding points to drive morphing. In other words, each
of the measured points 16 on the native portion 44 (in both rigid
and warp patches 48 and 50) is matched with the closest point on
the registered (transformed) computer model 18 as represented by
step 70. Transforming the computer model 18 in the warp patch 48
includes creating a set of virtual points in the transformed model
that are adjustable to achieve original design intent, new
optimized design, or a combination thereof. The registering and
rigid body transformation details are described in the subsequent
paragraph.
[0027] In the illustrated embodiment, the computer 20 obtains a
series of n (x, y, z) points measured on the native component
portion 44. The computer 20 then generates a series of n pairings
between the computer model 18 (X, Y, Z) points and the n series of
measured (x, y, z) points 16 on the native component portion 44.
Each of the n pairings between the computer model 18 and the
measured series of n points 16 substantially correspond to each
other. After generating the series of n pairings between the
computer model 18 points and the measured points 16 on the native
component portion 44, the computer 20 determines a plurality of
mapping functions for mapping point locations from the computer
model 18 to approximate measured locations of points on the native
component portion 44. Mathematical functions such as polynomial
functions, trigonometric functions or logical functions may be used
as the mapping functions. The computer 20 optimizes the mapping
functions to minimize the distance between the point locations of
the computer model 18 to the measured locations of points 16 on the
native component portion 44. Suitable mathematical functions may be
used as the optimization function. After optimizing the mapping
functions, the computer 20 then transforms the point locations from
the computer model 18 to the measured locations of points 16 on the
native component portion 44. In particular, the optimized functions
act as basis functions to transform the computer model coordinates
and vectors to reflect the deformations measured in the native
component portion 44. The transformation enables the original set
of computer model 18 points to reside on or substantially near the
actual measured points 16. The computer 20 generates a tensor for
morph using the transformed computer model points as represented by
the step 70. A tensor may be referred to as a generalized linear
`quantity` or `geometrical entity` that can be expressed as a
multi-dimensional array relative to a choice of basis of a
particular space on which it is defined.
[0028] Rigid body transformation is applied to cutter contact (CC)
points of the nominal tool path 36 as represented by the step 72.
In other words, after transforming the computer model 18 according
to the native component portion 44, the computer 20 modifies the
nominal tool paths 36 to the measured coordinate system of the
native component portion 44 according to the transformed computer
model. The nominal tool paths 36 include a plurality of points and
vectors in the nominal model coordinate system. After obtaining the
nominal tool paths 36, the computer 20 then obtains the optimized
mapping functions. The computer 20 applies the optimized mapping
functions to the nominal tool paths 36. The nominal tool path 36 is
registered to the set of virtual points created on the transformed
computer model. In particular, for each point and vector that
includes the nominal tool paths 36, the mapping functions move the
tool path into an appropriate orientation and position with respect
to the transformed model. After applying the optimized mapping
functions to the nominal tool paths 36, the computer 20 generates
the deformed tool paths. The tensor for morph is generated
according to the deformed cutter contact points 58 of the deformed
tool path 38 as represented by the step 74. As discussed
previously, in some exemplary embodiments, the nominal cutter
contact points 56 may be offset from the set of virtual points of
the transformed computer model to form the deformed cutter points
58 of the deformed tool path 38 for the purpose of matching
original design intent or creating new optimized shapes at the
point of repair or manufacture. The modification of the nominal
tool paths 36 results in the deformed tool paths 38, that the
controller 40 uses to control a particular machining/manufacturing
process. The controller 40 then uses the deformed tool paths 38 to
machine the component 12 according to the original deign intent,
new optimized design, or a combination thereof. After machining,
the measurement points 16 on the machined component 12 may again be
matched with the points on the computer model 18 to check for any
deviations for verification purpose as represented by step 78. The
exemplary technique disclosed herein may be used in a variety of
numerical control processes such as drilling, milling, turning,
inspecting, forging, non-contact measurement systems, surface
finishing systems, or the like.
[0029] Referring to FIG. 5, this figure is a flow chart
illustrating one exemplary embodiment of steps involved in adaptive
machining using computer software (e.g., code stored on a tangible
medium such as memory). In the illustrated embodiment, a first set
of measurement points 16 on a native component portion 44 is
measured using a measurement tool. A computer 20 receives the first
set of measurement points 16 from the measurement tool via a
communication port as represented by the step 80. The computer 20
also receives a computer model 18 of the component 12 via the
communication port. The computer 20 is then used to parse the
points data to obtain a points file as represented by the step 82.
In other words, the computer 20 determines the deviation between
the first set of measurement points 16 on the native portion 44 and
the second set of points of the computer model 18. The computer 20
classifies the first set of measurement points 16 on the component
12 into rigid patch 48 and warp patch 50.
[0030] The computer 20 then runs a registration software program as
represented by the step 84. The computer model 18 is registered to
the first set of measurement points 16. The computer model 18 is
subjected to rigid body transformation according to the rigid patch
48. The method further includes creating a set of corresponding
points to drive morphing. In other words, each of the measured
points on the native portion 44 (in both rigid and warp patches 48
and 50) is matched with the closest point on the registered
(transformed) computer model 18. The computer 20 then runs a tensor
program as represented by the step 86. The computer 20 generates a
tensor for morph using the transformed computer model points.
[0031] After transforming the computer model 18 according to the
native component portion 44, the computer 20 then runs a tool path
transformation program as represented by the step 88. The computer
20 modifies the nominal tool paths 36 to the measured coordinate
system of the native component portion 44 according to the
transformed computer model 18. After applying the optimized
appropriate mapping functions to the nominal tool paths 36, the
computer 20 generates the deformed tool paths 38. The tensor for
morph is generated according to the deformed cutter contact points
58 of the deformed tool path 38. The deformed tool path 38 is then
communicated to a machine tool via a communication port for
machining the component 12 as represented by the step 90.
[0032] While only certain features of the disclosure have been
illustrated and described herein, many modifications and changes
will occur to those skilled in the art. It is, therefore, to be
understood that the appended claims are intended to cover all such
modifications and changes as fall within the true spirit of the
disclosure.
* * * * *