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.

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.