Abstract: A method of machining a feature in a component using a machine having a support rotatable about a rotation axis and having a cutting tool movable relative to the component, the component being mounted on the support for rotation about a central axis of the component, the method includes: determining coordinates of at least three points on a reference surface of the component, the at least three points being circumferentially offset from one another relative to the central axis; determining an angular correction to apply to the cutting tool based on the coordinates of the at least three points; and machining the feature in the component using the cutting tool angled with the angular correction.

Abstract: A method for calibrating a machining system includes providing the machining system which includes a base, a cantilevered arm, and a rotary table positioned at the second arm end of the cantilevered arm. The rotary table is rotatable relative to the cantilevered arm about a first axis. The first axis has a first unloaded position and a first unloaded orientation with the machining system in an unloaded condition. The method further includes installing a measurement artifact on the rotary table, measuring a first position of the measurement artifact, and installing a load on the rotary table. The first axis has a first loaded position and a first loaded orientation with the machining system in a loaded condition. The method further includes measuring a second position of the measurement artifact and determining a positional deviation of the second position from the first position.

Abstract: A tool for validating a wire-electric-discharge-machining (wEDM) operation to be performed using a wEDM machine comprises a body including an engagement feature shaped to removably hold a validation coupon to be machined in the wEDM operation, the validation coupon sized larger than a size of a cut-out to be made in a part using the wEDM machine. A method of manufacturing the tool and a wEDM machine assembly are also provided.

Abstract: A method of wire electric discharge machining (wEDM) a feature in a part includes using wEDM, cutting and detaching a slug from a portion of the part that is to be detached from the part to define the feature, and thereby defining a validation cut-out in the portion, and using wEDM, cutting and detaching the portion having the validation cut-out from the part and thereby defining the feature.

Abstract: The method can include measuring the tridimensional positions of a reference feature for a first at least three different angular positions of the reference feature around the first rotation axis and a same first reference angular position around the second rotation axis, the reference feature being fixed relative to the component; and measuring the tridimensional positions of the reference feature for a second at least three different angular positions of the reference feature around the first rotation axis and a same second reference angular position around the second rotation axis.

Abstract: Methods and systems for wire-electro discharge machining of components are described. The method comprises machining a first component by moving a wire-EDM electrode along a first set of cutting paths associated with a plurality of cutting passes, the cutting paths determined based on a desired profile shape of the component, obtaining a cutting parameter of the first component post-machining, determining a first modified cutting path for a second component based on the cutting parameter, and machining the second component by moving the wire-EDM electrode along a second set of cutting paths associated with the plurality of cutting passes, the second set of cutting paths comprising the first modified cutting path.

Abstract: Methods of repairing a part having a firtree-shaped feature requiring rework are disclosed. An embodiment of the method includes receiving the part having the firtree-shaped feature requiring rework. The part is installed in a machine configured for wire electrical discharge machining (EDM). A location of the firtree-shaped feature relative to a datum of the machine is then determined. Wire EDM is performed on the firtree-shaped feature.

Abstract: A method of adding a feature to a part made of a metal alloy includes wire electric-discharge machining the feature into the part using a wire electrode having a zinc component to create a recast layer. After the step of wire electric-discharge machining the feature, at least some of the recast layer is removed by performing an electrochemical etching process that includes positioning a cathode adjacent the feature and passing current through a portion of the part that contains the feature.

Abstract: A method of wire-electric-discharge-machining (wEDM) a feature in a part includes using wEDM, cutting and detaching a slug from a portion of the part that is to be detached from the part to define the feature, and thereby defining a validation cut-out in the portion, and using wEDM, cutting and detaching the portion having the validation cut-out from the part and thereby defining the feature.

Abstract: A tool for validating a wire-electric-discharge-machining (wEDM) operation to be performed using a wEDM machine comprises a body including an engagement feature shaped to removably hold a validation coupon to be machined in the wEDM operation, the validation coupon sized larger than a size of a cut-out to be made in a part using the wEDM machine. A method of manufacturing the tool and a wEDM machine assembly are also provided.

Abstract: Methods of repairing a part having a firtree-shaped feature requiring rework are disclosed. An embodiment of the method includes receiving the part having the firtree-shaped feature requiring rework. The part is installed in a machine configured for wire electrical discharge machining (EDM). A location of the firtree-shaped feature relative to a datum of the machine is then determined. Wire EDM is performed on the firtree-shaped feature.

Abstract: Methods and systems for wire-electro discharge machining of components are described. The method comprises machining a first component by moving a wire-EDM electrode along a first set of cutting paths associated with a plurality of cutting passes, the cutting paths determined based on a desired profile shape of the component, obtaining a cutting parameter of the first component post-machining, determining a first modified cutting path for a second component based on the cutting parameter, and machining the second component by moving the wire-EDM electrode along a second set of cutting paths associated with the plurality of cutting passes, the second set of cutting paths comprising the first modified cutting path.

Abstract: The method can include measuring the tridimensional positions of a reference feature for a first at least three different angular positions of the reference feature around the first rotation axis and a same first reference angular position around the second rotation axis, the reference feature being fixed relative to the component; and measuring the tridimensional positions of the reference feature for a second at least three different angular positions of the reference feature around the first rotation axis and a same second reference angular position around the second rotation axis.

Abstract: A system and method of making a part, including capturing an actual tridimensional surface of each part to obtain a corresponding digitized actual surface, performing a tridimensional comparison between the digitized actual surface of each part and a nominal tridimensional surface, generating an actual location and orientation of an operation to be performed based on the tridimensional comparison, and performing the operation on the part based on the generated actual location and orientation of the element.

Abstract: A method of fabricating an integrally bladed rotor of a gas turbine engine according to one aspect, includes a 3-dimensional scanning process to generate a 3-dimensional profile of individual blades before being welded to the disc of the rotor. A blade distribution pattern on the disc is then determined in a computing process using data of the 3-dimensional profile of the individual blades such that the fabricated integrally bladed rotor is balanced.

Abstract: A method of fabricating an integrally bladed rotor of a gas turbine engine according to one aspect, includes a 3-dimensional scanning process to generate a 3-dimensional profile of individual blades before being welded to the disc of the rotor. A blade distribution pattern on the disc is then determined in a computing process using data of the 3-dimensional profile of the individual blades such that the fabricated integrally bladed rotor is balanced.

Abstract: A system and method of making a part, including capturing an actual tridimensional surface of each part to obtain a corresponding digitized actual surface, performing a tridimensional comparison between the digitized actual surface of each part and a nominal tridimensional surface, generating an actual location and orientation of an operation to be performed based on the tridimensional comparison, and performing the operation on the part based on the generated actual location and orientation of the element.

Abstract: A method of fabricating an integrally bladed rotor of a gas turbine engine according to one aspect, includes a 3-dimensional scanning process to generate a 3-dimensional profile of individual blades before being welded to the disc of the rotor. A blade distribution pattern on the disc is then determined in a computing process using data of the 3-dimensional profile of the individual blades such that the fabricated integrally bladed rotor is balanced.

Abstract: A system and method of making a part, including capturing an actual tridimensional surface of each part to obtain a corresponding digitized actual surface, performing a tridimensional comparison between the digitized actual surface of each part and a nominal tridimensional surface, generating an actual location and orientation of an operation to be performed based on the tridimensional comparison, and performing the operation on the part based on the generated actual location and orientation of the element.

Abstract: A method of fabricating an integrally bladed rotor of a gas turbine engine according to one aspect, includes a 3-dimensional scanning process to generate a 3-dimensional profile of individual blades before being welded to the disc of the rotor. A blade distribution pattern on the disc is then determined in a computing process using data of the 3-dimensional profile of the individual blades such that the fabricated integrally bladed rotor is balanced.