Abstract: Feed rate scheduling methods include measuring a topography of a grinding wheel of a machine tool, calculating a topography parameter using the topography, and calculating a feed rate scheduling parameter for a toolpath of the grinding wheel based on the topography parameter. The topography may be measured using microscopy. The topography parameter may include a plurality of parameters including a density of crystals at a given depth (C(h)) of the grinding wheel and/or an area fraction of crystals protruding at a given depth (?(h)) of the grinding wheel. The feed rate scheduling parameter may include a grinding wheel feed rate, a grinding wheel spin rate, and/or a grinding wheel cutting depth, among other parameters.

Abstract: A feed rate scheduling method may comprise: receiving an engagement geometry of a subtractive component for use in a computer numerical control (CNC) machining process; receiving a tool path for forming a component from a workpiece via the CNC machining process; calculating a plurality of bending moments of a spindle at various intervals along the tool path; and determining a feed rate schedule for the tool path of the subtractive component based on the plurality of bending moment.

Abstract: A method and apparatus for machining parts with variable stiffness includes determining, by a controller, a chatter-lobe plot of a cutter assembly. A preliminary tool path is developed by the controller. Virtual machining of a blank part using the preliminary tool path is performed by the controller. A chatter-lobe plot of the virtually machined part is determined by the controller. A dynamic chatter-lobe plot using the chatter-lobe plot of the cutting tool assembly and the chatter-lobe plot of the virtually machined part is determined by the controller. A chatter-free rotational speed of the cutting tool from the dynamic chatter-lobe plot is determined by the controller. A machining apparatus, controlled by the controller, uses the determined chatter-free rotational speed of the cutting tool to machine a blank part.

Abstract: A forming tool for forming leading edges of turbine blades is disclosed. In various embodiments, a forming tool may comprise a cylindrically-shaped body having a notch around the circumference of the cylindrically-shaped body. The notch may be positioned perpendicularly to a center axis of the cylindrically-shaped body. Further, the notch may have a notch contour with an upper notch contour and a lower notch contour, and where the notch contour is a relief of a selected turbine blade leading edge. The forming tool may be a grinding tool or a cutting tool. Moreover, a forming process may comprise forming, by a forming tool, a first portion of a turbine blade leading edge with a rough edge result, and forming, by a milling cutter, a second portion of the turbine blade leading edge with a rough edge result.

Abstract: A method and apparatus for machining parts with variable stiffness includes determining, by a controller, a chatter-lobe plot of a cutter assembly. A preliminary tool path is developed by the controller. Virtual machining of a blank part using the preliminary tool path is performed by the controller. A chatter-lobe plot of the virtually machined part is determined by the controller. A dynamic chatter-lobe plot using the chatter-lobe plot of the cutting tool assembly and the chatter-lobe plot of the virtually machined part is determined by the controller. A chatter-free rotational speed of the cutting tool from the dynamic chatter-lobe plot is determined by the controller. A machining apparatus, controlled by the controller, uses the determined chatter-free rotational speed of the cutting tool to machine a blank part.

Abstract: A forming tool for forming leading edges of turbine blades is disclosed. In various embodiments, a forming tool may comprise a cylindrically-shaped body having a notch around the circumference of the cylindrically-shaped body. The notch may be positioned perpendicularly to a center axis of the cylindrically-shaped body. Further, the notch may have a notch contour with an upper notch contour and a lower notch contour, and where the notch contour is a relief of a selected turbine blade leading edge. The forming tool may be a grinding tool or a cutting tool. Moreover, a forming process may comprise forming, by a forming tool, a first portion of a turbine blade leading edge with a rough edge result, and forming, by a milling cutter, a second portion of the turbine blade leading edge with a rough edge result.

Abstract: A forming tool for forming leading edges of turbine blades is disclosed. In various embodiments, a forming tool may comprise a cylindrically-shaped body having a notch around the circumference of the cylindrically-shaped body. The notch may be positioned perpendicularly to a center axis of the cylindrically-shaped body. Further, the notch may have a notch contour with an upper notch contour and a lower notch contour, and where the notch contour is a relief of a selected turbine blade leading edge. The forming tool may be a grinding tool or a cutting tool. Moreover, a forming process may comprise forming, by a forming tool, a first portion of a turbine blade leading edge with a rough edge result, and forming, by a milling cutter, a second portion of the turbine blade leading edge with a rough edge result.

Abstract: A forming tool for forming leading edges of turbine blades is disclosed. In various embodiments, a forming tool may comprise a cylindrically-shaped body having a notch around the circumference of the cylindrically-shaped body. The notch may be positioned perpendicularly to a center axis of the cylindrically-shaped body. Further, the notch may have a notch contour with an upper notch contour and a lower notch contour, and where the notch contour is a relief of a selected turbine blade leading edge. The forming tool may be a grinding tool or a cutting tool. Moreover, a forming process may comprise forming, by a forming tool, a first portion of a turbine blade leading edge with a rough edge result, and forming, by a milling cutter, a second portion of the turbine blade leading edge with a rough edge result.

Abstract: A method of machining includes mounting a part to a rotatable chuck of a lathe. A tool is then installed into the lathe. The tool is swung along an arcuate pathway to pass the tool through a smaller diameter area of the part to a larger diameter area of the part. The part is inserted into a cavity of the part. The part is then rotated and material is machine from the part.

Abstract: A method of designing a tool for forming a rotor blade including an airfoil portion includes generating a computer model of a rotor blade having an airfoil portion, and determining a curvature and radius of curvature at sections of the rotor blade. An inner and outer diameter of a circumferential forming portion of a tool operable to form the rotor blade may then be calculated. A method of designing a tool path for forming a rotor blade including an airfoil portion includes generating a computer model of a cylindrical tool operable to form a rotor blade including an airfoil portion and of a rotor having a plurality of the rotor blades. The computer models of the rotor and tool are used to generate a first and second tool motion corresponding to airfoil suction and pressure portions. A method of forming a rotor with integral blades is also disclosed.

Abstract: A method of designing a tool for forming a rotor blade including an airfoil portion includes generating a computer model of a rotor blade having an airfoil portion, and determining a curvature and radius of curvature at sections of the rotor blade. An inner and outer diameter of a circumferential forming portion of a tool operable to form the rotor blade may then be calculated. A method of designing a tool path for forming a rotor blade including an airfoil portion includes generating a computer model of a cylindrical tool operable to form a rotor blade including an airfoil portion and of a rotor having a plurality of the rotor blades. The computer models of the rotor and tool are used to generate a first and second tool motion corresponding to airfoil suction and pressure portions. A method of forming a rotor with integral blades is also disclosed.