A method for performing a cutting operation on a workpiece is provided. The method comprises providing a workpiece being made of a metal characterized by a thermal conductivity of no greater than about 100 W100 .sup.W/.sub.(m.Math.K) (approximately 57.8 .sup.Btu/.sub.(hr ft ° F.)), providing a cutting device comprising an internal cooling cavity defined on one side thereof by a thin-walled structure, and performing a cutting operation on the workpiece using the cutting device. The cutting speed is no less than about 500 .sup.m/.sub.min. (approximately 1640 .sup.ft/.sub.min).

A method for performing a cutting operation on a workpiece is provided. The method comprises providing a workpiece being made of a metal characterized by a thermal conductivity of no greater than about 100 W100 .sup.W/.sub.(m.Math.K) (approximately 57.8 .sup.Btu/.sub.(hr ft ° F.)), providing a cutting device comprising an internal cooling cavity defined on one side thereof by a thin-walled structure, and performing a cutting operation on the workpiece using the cutting device. The cutting speed is no less than about 500 .sup.m/.sub.min. (approximately 1640 .sup.ft/.sub.min).

A machining center is provided with: a base; a table that supports a workpiece; a main-shaft head that causes a tool to rotate around an axis of rotation of a main-shaft; a Z-axis drive device that causes the table to move with respect to the base along a Z axis parallel to the axis of rotation of the main-shaft; a W-axis drive device that causes the main-shaft head to move with respect to the base along a W axis parallel to the axis of rotation of the main-shaft; and a control device that controls the Z-axis drive device and the W-axis drive device so as to cause the tool to process the workpiece by causing the table and the main-shaft head to move along the Z axis and the W axis, respectively.

A machining center is provided with: a base; a table that supports a workpiece; a main-shaft head that causes a tool to rotate around an axis of rotation of a main-shaft; a Z-axis drive device that causes the table to move with respect to the base along a Z axis parallel to the axis of rotation of the main-shaft; a W-axis drive device that causes the main-shaft head to move with respect to the base along a W axis parallel to the axis of rotation of the main-shaft; and a control device that controls the Z-axis drive device and the W-axis drive device so as to cause the tool to process the workpiece by causing the table and the main-shaft head to move along the Z axis and the W axis, respectively.

A drilling system is provided for drilling a workpiece. The drilling system includes a pattern generator configured to apply a pattern on a workpiece surface of the workpiece at a reference location relative to a target drilling location. The drilling system includes a drilling end effector, which includes a chuck configured to hold a drilling tool. The drilling end effector also includes a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion that is configured to be held on the workpiece surface of the workpiece. The drilling end effector also includes a camera configured to acquire an image of an area of the workpiece surface that includes the pattern. The image acquired by the camera indicates whether the end portion of the nosepiece is aligned with the pattern on the workpiece surface.

A drilling system is provided for drilling a workpiece. The drilling system includes a pattern generator configured to apply a pattern on a workpiece surface of the workpiece at a reference location relative to a target drilling location. The drilling system includes a drilling end effector, which includes a chuck configured to hold a drilling tool. The drilling end effector also includes a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion that is configured to be held on the workpiece surface of the workpiece. The drilling end effector also includes a camera configured to acquire an image of an area of the workpiece surface that includes the pattern. The image acquired by the camera indicates whether the end portion of the nosepiece is aligned with the pattern on the workpiece surface.

Apparatus, systems, and methods for forming a plurality of aligned holes from a plurality of misaligned holes. The apparatus includes a reamer with a constant diameter a first portion and a tapered second portion. A constant diameter pilot member is connected to the reamer. The taper may be configured to center the reamer and reduce an offset between the apparatus and a centerline of a virtual hole created by the misaligned holes. The constant diameter of the pilot member corresponds to the virtual hole and the constant diameter of the first portion of the reamer correspond to a cleanup hole configured to accept an oversize fastener and fully encompass the misaligned holes. If the pilot member cannot pass through the misaligned holes, an apparatus with a smaller diameter pilot member and a larger diameter reamer is needed to create a cleanup hole that fully encompasses the misaligned holes.

Apparatus, systems, and methods for forming a plurality of aligned holes from a plurality of misaligned holes. The apparatus includes a reamer with a constant diameter a first portion and a tapered second portion. A constant diameter pilot member is connected to the reamer. The taper may be configured to center the reamer and reduce an offset between the apparatus and a centerline of a virtual hole created by the misaligned holes. The constant diameter of the pilot member corresponds to the virtual hole and the constant diameter of the first portion of the reamer correspond to a cleanup hole configured to accept an oversize fastener and fully encompass the misaligned holes. If the pilot member cannot pass through the misaligned holes, an apparatus with a smaller diameter pilot member and a larger diameter reamer is needed to create a cleanup hole that fully encompasses the misaligned holes.

A method for producing a diffusion cooling hole extending between a wall having a first wall surface and a second wall surface includes forming a cooling hole inlet at the first wall surface, forming a cooling hole outlet at the second wall surface, forming a metering section downstream from the inlet and forming a multi-lobed diffusing section between the metering section and the outlet. The inlet, outlet, metering section and multi-lobed diffusing section are formed by laser drilling, particle beam machining, fluid jet guided laser machining, mechanical machining, masking and combinations thereof.

A method for producing a diffusion cooling hole extending between a wall having a first wall surface and a second wall surface includes forming a cooling hole inlet at the first wall surface, forming a cooling hole outlet at the second wall surface, forming a metering section downstream from the inlet and forming a multi-lobed diffusing section between the metering section and the outlet. The inlet, outlet, metering section and multi-lobed diffusing section are formed by laser drilling, particle beam machining, fluid jet guided laser machining, mechanical machining, masking and combinations thereof.