Abstract: An apparatus and method for machining a workpiece in a single-pass comprising a tool configured to produce a borehole when rotated and translated relative to the workpiece, a toolholder configured to fixedly secure and rotate the tool, and a bushing retractably coupled to the toolholder, so as to be shiftable between extended and fully retracted positions, and preferably biased towards the extended position, wherein said tool, toolholder, and bushing are cooperatively configured such that the bushing provides lateral support for the tool during the machining process.

Abstract: A method and system are provided for non-contact evaluation of a machined surface of a cast-metal part, including a vision-based porosity inspection station. A digital image of the machined surface is acquired, oriented and scaled to an XY coordinate system, filtered, and inverted. A second image is generated with known design surface features eliminated. Each pixel of the inverted digital image is XOR-compared with a corresponding pixel of the second image. Identified common surface features common to both images is analyzed statistically for conformance to a threshold. A defect is identified as any identified surface feature common to both images which exceeds the threshold. The system moves the part for further processing if a statistical analysis of defects indicates an acceptable component, and alternatively, removes the part from further processing if the analysis indicates a flawed component.

Abstract: A system, method, and apparatus are provided for prioritizing the measurements made on manufactured parts while maintaining specified part quality standards. According to the method, system and apparatus, the process used by the CMM is modified so that the number of measurements made is reduced in accordance with the results of the analysis provided herein. A CMM apparatus is modified in accordance with the analysis results. A method for part measurement prioritization in a measuring system and method includes describing a set of features to be measured on a plurality of substantially identical parts, separating the set of features into sensitive features and non-sensitive features, dividing the non-sensitive features into a plurality of groups, and prioritizing the part measurements to measure the sensitive features and provide alternating measurements of the non-sensitive features.

Abstract: A multistage machining process includes a plurality of stations. Workpiece feature quality is predicted based on decomposition of the machining process into sources of variation, reticulation of the machining process into machining stations and error models that account for significant contributions to feature quality including from categorical sources of variation.

Abstract: A toolholder for a cutting tool is disclosed for use with a machine tool having a main shaft or spindle with a flared or tapered end socket. The toolholder has a tool-holding end for a cutting tool and a tapered shank end for placement in the tapered socket of the machine tool spindle. The toolholder also has an annular flange near its tapered shank, the flange or collar generally being used for location and gripping by a tool exchange mechanism. An elastic spacer ring is used and compressed between said flange and the face of said machine tool shaft in machining operations for dampening vibrations and flexing of the toolholder and cutting tool.