Laser Hole Machining Compensation for Deformed Drilling Surfaces

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing machining assemblies struggle to accurately drill holes in aircraft propulsion system components that deviate from their nominal shape due to manufacturing or operational deformations, leading to inconsistencies in hole size, shape, and orientation.

Innovation Solution

A CNC assembly with a machining system and controller that measures surface deviations from a 3D component model using a position measurement probe, calculates a compensation vector to adjust the laser source's stand-off position and orientation, and uses this information to accurately drill holes in deformed components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional machining assemblies are used to drill holes in components with surface deviations, then the machining process is simple, but the hole size, shape, and orientation accuracy deteriorates

Engineering Contradiction:

Improvehole size, shape, and orientation accuracyVSAvoidmachining system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system performs preliminary surface scanning and deviation measurement before the drilling operation. The controller calculates compensation vectors based on measured surface deviations from the nominal component model, preparing the corrected toolpath and laser source positioning data in advance to ensure accurate hole formation despite surface irregularities

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses a position measurement probe to scan the actual component surface and feed back the measured deviations to the controller. The controller then adjusts the laser source stand-off position and orientation based on this feedback, dynamically compensating for surface deviations to maintain manufacturing precision

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If the laser source stand-off position is not compensated for surface deviations, then the machining process is fast, but the hole orientation and size accuracy deteriorates

Engineering Contradiction:

Improvehole orientation accuracyVSAvoidmeasurement and compensation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically changes the laser source stand-off position and orientation parameters based on measured surface deviations. The controller adjusts these parameters using calculated compensation vectors, allowing the laser source to maintain optimal positioning and orientation relative to the actual component surface rather than the nominal model

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enables precise formation of component holes in deformed aircraft propulsion system components, ensuring accurate size, shape, and orientation within tight tolerance requirements, thereby improving machining efficiency and quality.

Implementation Method 1

form a component hole in the component using the laser source by directing a laser beam to the drilling surface with the laser source in the compensated laser source stand-off position and the compensated laser source orientation

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS20250114863A1Assembly and method for machining a component

Publication Date: 2025.04.10 PRATT & WHITNEY CANADA CORP

AI summary

A CNC assembly includes a machining system and a controller. The machining system includes at least one machining tool. The controller is configured to measure a surface deviation of a drilling surface of the component from a 3D component model for the component using a position measurement probe to identify a position of the drilling surface at a plurality of points, determine a compensation vector of a nominal hole for the drilling surface using the measured surface deviation, determine a compensated laser source stand-off position and a compensated laser source orientation for the nominal hole using the determined compensation vector, position a laser source in the compensated laser source stand-off position and the compensated laser source orientation, and form a component hole in the component using the laser source by directing a laser beam to the drilling surface with the laser source in the compensated laser source stand-off position and the compensated laser source orientation.