Abstract: A method of machining a workpiece may include continuously rotating the workpiece, continuously rotating a tool having at least one cutting surface, and positioning the tool relative to the workpiece so that the at least one cutting surface engages the workpiece at a first discrete location at a periphery of the workpiece. The method may further include continuing to rotate the workpiece and the tool so that the at least one cutting surface engages a second discrete location at the periphery of the workpiece, and controlling a tool surface velocity VT relative to the workpiece surface velocity VW so that the first and second discrete locations are discontinuous. The tool may make multiple iterative passes over the workpiece to engage subsequent discrete locations, wherein the first discrete location, second discrete location, and multiple subsequent discrete locations may form a machined surface that extends continuously around the workpiece.

Abstract: A system is provided for manufacturing a part. The system includes a manufacturing machine that includes at least one additive manufacturing tool. The system further includes a computer numerical control (CNC) controller operatively associated with the manufacturing machine and configured to control the at least one additive manufacturing tool based on computer aided manufacturing (CAM) instructions. The system further includes a CAM controller operatively associated with the CNC controller and configured to determine the CAM instructions based on computer aided drafting (CAD) instructions, the CAM instructions including a plurality of CAM operation control functions, each of the plurality of CAM operation control functions correlated with at least one of a plurality of CAD operation control functions of the CAD instructions.

Abstract: A system is provided for manufacturing a part. The system includes a manufacturing machine that includes at least one additive manufacturing tool. The system further includes a computer numerical control (CNC) controller operatively associated with the manufacturing machine and configured to control the at least one additive manufacturing tool based on computer aided manufacturing (CAM) instructions. The system further includes a CAM controller operatively associated with the CNC controller and configured to determine the CAM instructions based on computer aided drafting (CAD) instructions, the CAM instructions including a plurality of CAM operation control functions, each of the plurality of CAM operation control functions correlated with at least one of a plurality of CAD operation control functions of the CAD instructions.

Abstract: A method of machining a workpiece may include continuously rotating the workpiece, continuously rotating a tool having at least one cutting surface, and positioning the tool relative to the workpiece so that the at least one cutting surface engages the workpiece at a first discrete location at a periphery of the workpiece. The method may further include continuing to rotate the workpiece and the tool so that the at least one cutting surface engages a second discrete location at the periphery of the workpiece, and controlling a tool surface velocity VT relative to the workpiece surface velocity VW so that the first and second discrete locations are discontinuous. The tool may make multiple iterative passes over the workpiece to engage subsequent discrete locations, wherein the first discrete location, second discrete location, and multiple subsequent discrete locations may form a machined surface that extends continuously around the workpiece.

Abstract: A processing head assembly is provided for use with a movable tool holder of a machine tool. The processing head assembly includes an upper processing head coupled to the movable tool holder and having a body defining a socket, and a feed powder/propellant port coupled to the body and operably coupled to a feed powder/propellant supply. The processing head assembly further includes a lower processing head having a base configured to be releasably coupled to the socket, and a nozzle coupled to the base and defining a feed powder/propellant interface configured to detachably couple to the feed powder/propellant port and a nozzle exit orifice.

Abstract: A method of machining a workpiece may include continuously rotating the workpiece, continuously rotating a tool having at least one cutting surface, and positioning the tool relative to the workpiece so that the at least one cutting surface engages the workpiece at a first discrete location at a periphery of the workpiece. The method may further include continuing to rotate the workpiece and the tool so that the at least one cutting surface engages a second discrete location at the periphery of the workpiece, and controlling a tool surface velocity VT relative to the workpiece surface velocity VW so that the first and second discrete locations are discontinuous. The tool may make multiple iterative passes over the workpiece to engage subsequent discrete locations, wherein the first discrete location, second discrete location, and multiple subsequent discrete locations may form a machined surface that extends continuously around the workpiece.

Abstract: Methods and apparatus for performing additive manufacturing processes using a machine tool may include controlling an orientation of a processing head to control the tangential angle of a fabrication energy beam, a feed powder nozzle, or both. The orientation of a non-circular energy beam may be control to more evenly distribute the energy beam across a width of a tool path. Additionally or alternatively, the orientation of the feed powder nozzle may be controlled to project toward a powder target that is spaced from a beam target. The powder target may be directed to a trailing edge of a beam spot formed by the energy beam to increase the amount of powder incorporated into a melt pool formed by the energy beam. Alternatively, the powder target may be directed to a leading edge of the beam spot to provide a self-correcting feature to address thickness errors formed in previous layers of added material.

Abstract: A method of grind hardening a workpiece is provided. The method may include securing the workpiece in a workpiece retainer and a grind tool in a tool retainer, rotating the grind tool in a first angular direction at a first angular speed, controlling the workpiece and tool retainers such that the grind tool engages the workpiece, and controlling the workpiece and tool retainers such that the grind tool is guided along a grinding track of the workpiece. The grind tool may engage and/or disengage the workpiece at portions of sacrificial material disposed thereon. Coolant and cleaning nozzles may be provided and controlled such that at least a portion of the coolant from the coolant nozzle is diverted to the cleaning nozzle in a manner which reduces heat dissipation, improves thermal efficiency of the grind hardening and reduces loading of the grind tool.

Abstract: An apparatus for obtaining information about a workpiece may include a measuring device having a nozzle defining an orifice in fluid communication with a source of incompressible fluid. A fluid monitoring apparatus may monitor a parameter of the substantially incompressible fluid, and a pump may be fluidly coupled to the source and configured to supply incompressible fluid to the orifice. The pump may have a pump chamber with a first displacement setting having a first fixed volume, so that operation of the pump at a first pump speed with the pump chamber in the first displacement setting generates a first fluid flow having a substantially constant first volumetric rate. The pump may have more than one displacement setting, or the pump may be operated at different speeds to change the volumetric flow rate. The nozzle may include multiple, independent orifice sets that may be selectively provided fluid, thereby to obtain information on different parts of the workpiece with a single placement of the nozzle.

Abstract: Gear machining apparatus and methods are configured to produce gaps between gear teeth having portions formed by two different machining processes. A rough cutting process may be used to form a root portion of the gap, while a finish cutting process may be used to form final tooth faces. The apparatus and methods may further be configured to machine one or more gear tooth profile modifications.

Abstract: A cutting insert rotated about its axis may be utilized during a metalworking operation and applied against the rotating workpiece to enhance tool performance. The cutting insert is secured within a toolholder having features to secure the insert but at the same time make for efficient removal of the insert from the toolholder.

Abstract: A method of grind hardening a workpiece is provided. The method may include securing the workpiece in a workpiece retainer and a grind tool in a tool retainer, rotating the grind tool in a first angular direction at a first angular speed, controlling the workpiece and tool retainers such that the grind tool engages the workpiece, and controlling the workpiece and tool retainers such that the grind tool is guided along a grinding track of the workpiece. The grind tool may engage and/or disengage the workpiece at portions of sacrificial material disposed thereon. Coolant and cleaning nozzles may be provided and controlled such that at least a portion of the coolant from the coolant nozzle is diverted to the cleaning nozzle in a manner which reduces heat dissipation, improves thermal efficiency of the grind hardening and reduces loading of the grind tool.

Abstract: A method of machining a workpiece may include continuously rotating the workpiece, continuously rotating a tool having at least one cutting surface, and positioning the tool relative to the workpiece so that the at least one cutting surface engages the workpiece at a first discrete location at a periphery of the workpiece. The method may further include continuing to rotate the workpiece and the tool so that the at least one cutting surface engages a second discrete location at the periphery of the workpiece, and controlling a tool surface velocity VT relative to the workpiece surface velocity VW so that the first and second discrete locations are discontinuous. The tool may make multiple iterative passes over the workpiece to engage subsequent discrete locations, wherein the first discrete location, second discrete location, and multiple subsequent discrete locations may form a machined surface that extends continuously around the workpiece.

Abstract: The present invention broadly comprises a method of establishing parameters of a balancer to predict part unbalance on a computer numerically controlled machine comprising the steps of varying unbalance of the balancer and measuring vibration to develop influence parameters of the balancer, varying unbalance of a test part and measuring vibration to develop influence parameters of the test part, comparing the influence parameters of the balancer and the test part, and, determining a range of test part unbalance over which the influence parameters of the balancer and the test part approximately match. The present invention also broadly comprises a system for machining and balancing a workpiece comprising a computer numerically controlled machine, and, a rotating balancer assembly arranged to determine a measurement of unbalance when a first initial vibration measured by a first vibration sensor exceeds a limited range of vibration sensed by the first vibration sensor.

Abstract: An apparatus for obtaining information about a workpiece may include a measuring device having a nozzle defining an orifice in fluid communication with a source of incompressible fluid. A fluid monitoring apparatus may monitor a parameter of the substantially incompressible fluid, and a pump may be fluidly coupled to the source and configured to supply incompressible fluid to the orifice. The pump may have a pump chamber with a first displacement setting having a first fixed volume, so that operation of the pump at a first pump speed with the pump chamber in the first displacement setting generates a first fluid flow having a substantially constant first volumetric rate. The pump may have more than one displacement setting, or the pump may be operated at different speeds to change the volumetric flow rate. The nozzle may include multiple, independent orifice sets that may be selectively provided fluid, thereby to obtain information on different parts of the workpiece with a single placement of the nozzle.

Abstract: A turning method and apparatus includes a tool holding mechanism, such as a turret, and a workpiece holder, typically a chuck disposed on a main machine spindle. The tool holding mechanism may be translated in three directions relative to the workpiece holder, including a Z-direction that is along the axis of the rotation of the workpiece holder and X- and Y-directions orthogonal thereto. Under the control of the computer control system, the tool holding mechanism is moved in a direction having both an X- and Y-component relative to the workpiece holder.

Abstract: Disclosed are a computer numerically controlled incompressible machine and related methods. The machine includes a measuring device that has a source of fluid that is fluidically communicable with a nozzle and that configured to deliver fluid at a constant volumetric flow rate when a measurement reading is taken. The pressure of fluid delivered to the nozzle is monitored and, from this pressure, a measurement parameter is determined. Other embodiments are disclosed; for instance, the invention in some embodiments provides an integrated cutting tool and nozzle.

Abstract: Disclosed are a computer numerically controlled machine and methods for forming, grinding, or dressing cutting tools in a computer numerically controlled machine. In some embodiments, the computer numerically controlled machine is provided with a cutting tool and an abrasive surface. The abrasive surface is brought into contact with the cutting tool to abrade material from the cutting tool in a grinding or dressing operation. In certain embodiments, it is not necessary to remove the cutting tool from the computer numerically controlled machine for dressing. In some non-mutually-exclusive embodiments, the machine is provided with tool blanks, from which cutting tools are prepared using an abrasive surface in the machine.

Abstract: A cutting insert rotated about its axis may be utilized during a metalworking operation and applied against the rotating workpiece to enhance tool performance. The cutting insert is secured within a toolholder having features to secure the insert but at the same time make for efficient removal of the insert from the toolholder.

Abstract: Disclosed are a turning method and apparatus. The apparatus, which otherwise may be conventional, includes a tool holding mechanism, such as a turret, and a workpiece holder, typically a chuck disposed on a main machine spindle. The tool holding mechanism may be translated in three directions relative to the workpiece holder, including a Z direction that is along the axis of the rotation of the workpiece holder and X and Y directions orthogonal thereto. Under the control of the computer control system, the tool holding mechanism is moved in a direction having both an X- and Y-component relative to the workpiece holder.