Abstract: A method for detecting misalignment of initially-aligned fiber filaments in a composite. An optical fiber is placed among the fiber filaments in the composite, light is directed into the optical fiber, the intensity of the light in the optical fiber is measured during subsequent composite processing, and attenuation in such light intensity is ascertained which indicates such misalignment (e.g., wrinkling, bending, buckling, porosity, delamination and the like) is being detected during such processing. In another preferred method, before-processing and after-processing x-ray images are taken of an x-ray-attenuating fiber which has been placed among x-ray-transparent fiber filaments in a composite.

Abstract: This invention discloses a system and method for measuring and monitoring three-dimensional shaped objects with projections of computer models of the objects. The computer models of the three-dimensional shaped objects are in the form of grid patterns. An image of the computer model of grid patterns is simultaneously projected from a dual projection system in two directions onto a real world instance of the object. Any variation between the computer model and the real world instance of the object is highlighted directly on the object by interference patterns of the two projections on the real world instance. The variation is quantified by counting the number of interference patterns on the real world instance of the object.

Abstract: A method for detecting misalignment of initially-aligned fiber filaments in a composite. An optical fiber is placed among the fiber filaments in the composite, light is directed into the optical fiber, the intensity of the light in the optical fiber is measured during subsequent composite processing, and attenuation in such light intensity is ascertained which indicates such misalignment (e.g., wrinkling, bending, buckling, porosity, delamination and the like) is being detected during such processing. In another preferred method, before-processing and after-processing x-ray images are taken of an x-ray-attenuating fiber which has been placed among x-ray-transparent fiber filaments in a composite.

Abstract: A method for determining an adaptive feedrate for a machine tool used to machine a workpiece initially cut from stock using a stock-cutting program. Initial workpiece geometry is obtained from a geometry modeling program using the stock-cutting NC program as an input. Such automatically-generated initial workpiece geometry is used to derive adjusted (i.e., adaptive) feedrates in accordance with a known method.

Abstract: A lightweight, impact-resistant gas turbine blade, such as an aircraft engine fan blade, has an airfoil portion which includes a metal section and at least one foam section which together define a generally airfoil shape. The metal section extends from generally the blade root to generally the blade tip. A composite skin generally completely surrounds, and is bonded to, the metal section and the at-least-one foam section. Preferably, an erosion coating generally completely surrounds, and is bonded to, the composite skin.

Abstract: A system and method for precisely superimposing images of computer models in three-dimensional space to a corresponding physical object in physical space. The system includes a computer for producing a computer model of a three-dimensional object. A projector means projects an image of the computer model onto the physical object. A spatial transformation accurately maps the computer model onto a projection stage at the projector which projects a formed image in a three-dimensional space onto the physical object in a one-to-one correspondence.

Abstract: A computerized process to generate ply patterns for manufacturing industrial parts by stacking and molding a large number of plies is based on solid modeling. The outermost shell of the part is unfolded to a planar pattern using a surface development procedure. The part is decomposed based on the ply thickness; the shell with the ply thickness is removed from the solid model once the surface is unfolded. A set of ply patterns are formed by repeating the unfolding process until no more volume remains. More accurate patterns are produced in less time, especially plies for complexly shaped composite parts such as aircraft engine components.

Abstract: An adaptive feedrate control and method of optimizing the metal removal rate of NC end milling is based on a solid modeler which continuously simulates the in-process workpiece geometry in 3-dimensional machining. For each NC record representing a tool motion, an adjusted feedrate is generated off-line by the simulation running on a general purpose computer. The metal removal rate, cutting force, and tool deflection are calculated, and a feedrate is chosen to increase machine utilization without violating user-set constraints and avoid common machine problems such as excessive tool deflection and tool breakage.