Aircraft Engine Part Machining with 3D Reference Alignment
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Solution Overview
Problem
Existing methods for manufacturing aircraft engine parts face challenges in establishing a common coordinate system for complex parts with multiple precision features, particularly when machining reference features are obstructed by fixtures, leading to high costs and imprecision.
Innovation Solution
A method involving the creation of a tri-dimensional model to determine the geometrical relationship between machining and setup reference features, using a computer measurement machine to measure and compute the position and orientation of the machining reference feature, and applying a coordinate transformation to correct the CNC machine's coordinate system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a common coordinate system is established for complex parts with multiple precision features, then manufacturing precision is improved, but device complexity increases due to the need for multiple fixtures and coordinate transformations
Solution Approach 1:
A reference feature is introduced as an intermediary element that connects the machining feature and setup feature. The reference feature serves as a common coordinate system basis, allowing precise transformation between different feature coordinate systems without requiring complex multi-fixture arrangements. The reference feature acts as a mediator that simplifies the coordinate transformation process while maintaining manufacturing precision.
Solution Approach 2:
The invention creates a digital model (copy) of the part containing all features including the reference feature. This digital representation allows virtual establishment of coordinate systems and transformations before actual machining, reducing the need for physical trial-and-error with complex fixtures. The digital copy enables precise calculation of coordinate transformations without physical complexity.
2Manufacturing precision
If high-precision fixtures are used to maintain coordinate accuracy, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The invention replaces expensive high-precision physical fixtures with a digital model containing all geometric information. The coordinate transformations are calculated mathematically from the digital model rather than being physically enforced by costly precision fixtures. This digital copying approach maintains coordinate accuracy while significantly reducing manufacturing costs.
Solution Approach 2:
The invention changes the approach from physical parameter control (fixture precision) to digital parameter control (coordinate transformation calculations). By transforming the problem from a physical precision maintenance issue to a computational geometry issue, the need for expensive high-precision fixtures is eliminated while maintaining the required coordinate accuracy.
3Ease of manufacture
If multiple machining operations are performed on different fixtures, then ease of manufacture is improved, but measurement precision deteriorates due to difficulty in establishing common coordinate system
Solution Approach 1:
The reference feature serves as a persistent intermediary that remains consistent across multiple machining operations and fixtures. All coordinate transformations are referenced to this common reference feature, ensuring that measurements and machining on different fixtures can be accurately correlated. This mediator approach maintains measurement precision while allowing operational flexibility.
Solution Approach 2:
The reference feature and its associated coordinate system serve multiple functions across different machining operations and fixtures. Rather than requiring separate coordinate systems for each fixture or operation, the universal reference feature enables a single coordinated approach to multiple machining tasks, maintaining measurement precision while improving ease of manufacture.
Data Source
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AI summary
The method can include mounting the part (34) on a machining fixture (46), obtaining a geometrical relationship between a machining reference feature (42) of the part (34) and a setup reference feature (40) of the part (34), such as via a 3D model acquired by scanning, measuring a position and orientation of the setup reference feature (40) relative the machining fixture (46), computing a position and orientation of the machining reference feature (42) based on the geometrical relationship and on the measured position and orientation; and machining the target feature (44) of the part (34) relative to the computed position and orientation of the machining feature (42).