A system for automated adaptive manufacturing of airfoil castings is disclosed. The system may receive a three dimensional scan of a work piece. The system may compare the three dimensional scan to a digital model of the work piece. The system may identify an area of dimensional abnormality on the work piece based on the comparison. The system may alter the area of dimensional abnormality on the work piece.

Provided is a method of manufacturing wind turbine rotor blades, wherein each rotor blade includes an inboard section and an outboard section, and wherein an inboard blade section including a root end and a transition region is manufactured using a first casting process; and an outboard blade section including an airfoil region is manufactured using a second casting process, which second casting process is different from the first casting process. The invention further describes a wind turbine rotor blade manufactured using such a method.

A method of machining a surface of a component. The method comprises scanning the surface of the component to obtain scanned electronic 3D data representing the scanned surface of the component locating a surface defect of the scanned surface and identifying a defect region that surrounds and includes the surface defect, and providing electronic 3D data representing a patch having the desired shape of the defect region. The method also comprises transforming the patch to generate a tooling path for repairing the surface defect. The transformation comprising translating a plurality of nodes of the patch. The translation distance of each node based on the distance of that node from an origin node of the patch. The method further comprises machining the surface of the component according to the generated tooling path.

A method for producing an integrally bladed rotor includes providing imaginary front and rear lattice points on the ridges of the front and rear edges; providing a first imaginary line on positive-pressure and negative-pressure surfaces to connect a first imaginary front lattice point and a first imaginary rear lattice point; providing a second imaginary line on the positive-pressure and negative-pressure surfaces to connect a second imaginary front lattice point next to the first imaginary front lattice point and a second imaginary rear lattice point next to the first imaginary rear lattice point; providing a spiral path on the positive-pressure and negative-pressure surfaces by connecting the first and second imaginary lines with a spiral curve; and cutting the positive-pressure and negative-pressure surfaces by moving a cutting point corresponding to a cutting edge of a turning tool along the spiral path. point around the blade.

There are provided a system and a method of use thereof for executing a manufacturing process. For example, a method can include executing, by a system configured to drive the manufacturing process, a set of manufacturing functions based on a digital model of a first part. The method can include fetching, by the system, from an in-field scoring system, performance data relating to a second part. The method can further include constructing the digital model based on the performance data relating to the second part. The method can further include generating, based on the digital model, a forecast representative of a performance of the first part and generating the set of manufacturing functions based on the digital model and the forecast. The method further includes manufacturing the first part according to the set of manufacturing functions.

The invention relates to a method and to system for producing blades (1) of a machine interacting with a fluid, in particular a fluid-driven machine, in particular a wind turbine, comprising an examination device (19) for determining geometric deviations (A, B, C, D, E, F) from a target shape for one or more shaped blades (1), a device (21) for determining a deviation evaluation of one or more determined geometric deviations from the target shape for each blade with respect to the aerodynamic and/or mechanical consequences thereof, a device (23) for assigning one or more corrective measures (100, 101, 102), each including an expenditure evaluation (100″, 101″, 102″), to one or more determined geometric deviations (A, B, C, D, E, F) from the target shape for each blade, and a linking device (24) for linking a deviation evaluation that was determined for one or more of the determined geometric deviations to the expenditure evaluation for one or more determined corrective measures and for determining the corrective measures to be carried out from the result of the linkage.

Systems and methods that include and/or leverage a cluster of machine-learned models to recontour components of gas turbine engines are provided. In one exemplary aspect, the systems and methods leverage a cluster of machine-learned models to predict repair machining offsets for certain sections of the component that can be used to adjust or set a material removal tool path.

A method of removing features from a cast workpiece includes generating a nominal toolpath for machining the cast workpiece. The cast workpiece is mounted onto a platform of a computer numeric control machine. The cast workpiece is inspected with a probe to generate probe data. Features to be removed are identified based upon the probe data generated during the inspection. Any expected features of the cast workpiece that are missing from the cast workpiece are identified. A transformation matrix is applied to the nominal toolpath with a controller of the computer numeric control machine, wherein the transformation matrix is based upon the probe data. Alignment of the cast workpiece is adjusted relative to the computer numeric control machine based on the transformation matrix with the computer numeric control machine. Features are removed from the cast workpiece that were identified during inspection.

A method of manufacturing an aerodynamic element with an edge is provided. The method includes producing the aerodynamic element with an initial condition, cooling the aerodynamic element, generating a predefined number of data points sufficient to characterize contours of the edge and comparing the data points to a nominal condition to derive transformation parameters applicable to cutting toolpaths to adapt the cutting toolpaths to the initial condition.

Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design and manufacture of physical structures using subtractive manufacturing systems and techniques and a determined stock allowance include, in one aspect, a method including: obtaining a finishing toolpath specification for three dimensional (3D) geometry of a part; generating 3D geometry of a model of a semi-finished structure in accordance with a computer simulation of deflections experienced by a workpiece as stock material is cut from the workpiece using the finishing toolpath specification; creating a semi-finishing toolpath specification for the semi-finished structure; and providing the semi-finishing toolpath specification for use in machining the part by cutting away a first portion of the stock material using the semi-finishing toolpath specification to form the semi-finished structure, followed by performing a finishing operation of the semi-finished structure by cutting away a second portion of the stock material to form the part.