Abstract: A method for fabricating a component using a tool is provided. The method includes determining a model tool contact path for the component based on a component geometry, nominal tool tip path, tool geometry, the component geometry including a grid system having a plurality of elements and nodes at an intersection of the elements. The method also includes measuring a geometric property of the component relative to the model component geometry, generating a tool contact path and tool tip path corresponding to the measured geometric property, and at least partially fabricating the component using the generated tool contact path.

Abstract: A method for fabricating a component using a tool includes determining an actual property of a region of the component, comparing the actual property of the region of the component with an expected property of the region to determine a difference between the actual property and the expected property, and updating a path of the tool that is electronically stored in a memory and executable by a processor for fabricating the component based on the difference between the actual property and the expected property of the region.

Abstract: A metal machining apparatus for removal of metal from a workpiece, that employs a laser-targeted coolant nozzle to apply coolant fluid to a machining tool, such as a grinding wheel, to remove metal from a workpiece. The laser-targeted coolant nozzle has a coolant nozzle body having a flow passage for the coolant fluid, and a laser bore through which a visible laser can be inserted. The visible laser cooperates with a positioning feature on the nozzle body for visually positioning the coolant nozzle relative to the grinding wheel. When the laser is removed and replaced with a seal plug, the stream of cooling fluid passing through the flow passage can be directed accurately at the grinding wheel for improved workpiece grinding.

Abstract: A manufacturing cell having a plurality of work stations, where at least one of the work station comprises a metalworking machine, and where at least one metalworking machine is provided with a modular tooling apparatus. The modular tooling apparatus consists of a base having one or more attachment surfaces, and one or more inserts that can be inserted semi-permanently to the attachment surfaces. The attachment surface is typically a pocket in the surface of the base. The insert has a workpiece support feature that can support and/or secure the workpiece into the proper position and orientation for machining. The base, pockets and inserts are configured to provide a characteristic location and orientation for the workpiece relative to the base, and to the metalworking machine.

Abstract: A metal machining apparatus for removal of metal from a workpiece, that employs a laser-targeted coolant nozzle to apply coolant fluid to a machining tool, such as a grinding wheel, to remove metal from a workpiece. The laser-targeted coolant nozzle has a coolant nozzle body having a flow passage for the coolant fluid, and a laser bore through which a visible laser can be inserted. The visible laser cooperates with a positioning feature on the nozzle body for visually positioning the coolant nozzle relative to the grinding wheel. When the laser is removed and replaced with a seal plug, the stream of cooling fluid passing through the flow passage can be directed accurately at the grinding wheel for improved workpiece grinding.

Abstract: A manufacturing cell having a plurality of work stations, where at least one of the work station comprises a metalworking machine, and where at least one metalworking machine is provided with a modular tooling apparatus. The modular tooling apparatus consists of a base having one or more attachment surfaces, and one or more inserts that can be inserted semi-permanently to the attachment surfaces. The attachment surface is typically a pocket in the surface of the base. The insert has a workpiece support feature that can support and/or secure the workpiece into the proper position and orientation for machining. The base, pockets and inserts are configured to provide a characteristic location and orientation for the workpiece relative to the base, and to the metalworking machine.

Abstract: A method and apparatus of retaining a gas turbine engine blade in a fixed predetermined position includes the following steps: inserting an airfoil portion of the gas turbine engine blade within a device so as to be loosely held therein; orienting the gas turbine engine blade so as to have a predetermined relationship with the device; providing an initial clamping force on the device so as to retain the gas turbine engine blade in the predetermined position; and, actuating a mechanism associated with the device to provide a fixed clamping force on the airfoil portion so that the gas turbine engine blade is retained in the predetermined position.

Abstract: A method and apparatus of retaining a gas turbine engine blade in a fixed predetermined position includes the following steps: inserting an airfoil portion of the gas turbine engine blade within a device so as to be loosely held therein; orienting the gas turbine engine blade so as to have a predetermined relationship with the device; providing an initial clamping force on the device so as to retain the gas turbine engine blade in the predetermined position; and, actuating a mechanism associated with the device to provide a fixed clamping force on the airfoil portion so that the gas turbine engine blade is retained in the predetermined position.

Abstract: A modular tooling apparatus for performing a metalworking operation on a workpiece or a family of workpieces. The modular tooling apparatus consists of a base having one or more attachment surfaces, and one or more inserts that can be inserted semi-permanently to the attachment surfaces. The attachment surface is typically a pocket in the surface of the base. The insert has a workpiece support feature that can support and/or secure the workpiece into the proper position and orientation for machining. The base, pockets and inserts are configured to provide a characteristic location and orientation for the workpiece relative to the base, and to the metalworking machine. The modular tooling apparatus permits machining a family of workpiece members that are related but different in detail, by inserting the insert member from the family of inserts to properly position and orient the corresponding workpiece member, without needing to change, disconnect, or move the base tooling.

Abstract: A manufacturing cell having a plurality of work stations, where at least one of the work station comprises a metalworking machine, and where at least one metalworking machine is provided with a modular tooling apparatus. The modular tooling apparatus consists of a base having one or more attachment surfaces, and one or more inserts that can be inserted semi-permanently to the attachment surfaces. The attachment surface is typically a pocket in the surface of the base. The insert has a workpiece support feature that can support and/or secure the workpiece into the proper position and orientation for machining. The base, pockets and inserts are configured to provide a characteristic location and orientation for the workpiece relative to the base, and to the metalworking machine.

Abstract: A modular tooling apparatus for performing a metalworking operation on a workpiece, having a base comprising an attachment surface having a locating feature, a removable insert separably secured to the attachment surface, having a locating feature and a workpiece support feature on a surface thereof, and an extraction/locking device movable between a first position wherein the insert is secured to the attachment surface, whereby the locating feature of the insert associates with the locating feature of the attachment surface, and a second position wherein the insert is at least partially extracted from the attachment surface. The extraction/locking device alternately secures an insert to the base and assists in extracting the insert from the base. The device provides for ease of removal of an insert when the upper portion does not provide convenient surfaces for a technician to grab.

Abstract: An integrated compressor disk and compressor blade (BLISK) having a specified shape is prepared by an electrochemical machining process having a cathode defined by a set of cathode shape parameters. A trial BLISK is prepared using a cathode defined by a set of trial shape parameters, and a set of deviations of the trial shape from the specified shape at a plurality of surface grid points on a surface of the trial article is measured. A set of revised cathode shape parameters is determined using at least one reshaping routine specific to the BLISK. A reshaped article is prepared using the electrochemical machining process and a reshaped cathode defined by the revised cathode shape parameters.