A hand-held through-skin (HHTS) sensor for determining the location of an underlying aperture in a support structure suited to mount a skin or surface. In an embodiment, the HHTS sensor includes a sensor disposed in a housing and configured to determine a location of an aperture disposed in an adjacent surface through electromagnetic, x-ray, ultrasonic or other means. The HHTS sensor further includes an alignment assembly having an alignment orifice disposed in the housing and configured to be maneuvered in an x-y plane within the housing. The HHTS sensor also includes a processor coupled to the sensor and configured to receive a signal from the sensor indicating the location of the aperture and configured to control first and second actuators to maneuver the alignment orifice within the x-y plane to be co-axially located with the aperture in response to the sensor signal.

A method for processing a workpiece on a numerically controlled machine tool by a tool includes the steps of: controlling a relative movement of the tool relative to the workpiece for processing the workpiece, producing an ultrasonic vibration of the tool by an ultrasonic generator, detecting at least one sensor signal outputted from the ultrasonic generator and identifying a change in the material at the workpiece while controlling the relative movement of the tool relative to the workpiece on the basis of the at least one sensor signal outputted from the ultrasonic generator.

A cutting guide device for ultrasonic cutting of workpieces is provided. The cutting guide device includes a cutting edge with a cutting edge longitudinal axis held in the cutting guide device, an ultrasound generator which oscillates the cutting edge, a control unit which controls movement of the cutting edge on a cutting path, and a first force measuring device which measures an actual lateral force on the cutting edge transverse to the cutting edge longitudinal axis and transverse to the cutting direction. The first force measuring device sends actual lateral force measurement values to the control unit, which changes at least one cutting parameter based on the measured actual lateral force. A method for using the ultrasonic cutting device is also provided.

A method of machining ceramic matrix composite components includes providing an ultrasonic vibration tool having a tool tip, and exciting the tool by providing a control current, such that the tool tip is repeatedly vibrated towards and away from a ceramic matrix composite workpiece. A slurry feed is supplied including abrasive particles to a surface to be machined by the tool tip. A vibration amplitude of the tool tip is controlled by sensing load on the tool and communicating with a computing device. The computing device controls the vibration amplitude of the tool tip. The computing device is provided with at least one memory programmed with historic data, and is operable to modify the vibration amplitude signal being sent to the tool, and comparing resulting load levels due to the change in vibration amplitude signals, and storing the change in vibration amplitude signals at the memory.

A cutting guide device for ultrasonic cutting of workpieces is provided. The cutting guide device includes a cutting edge with a cutting edge longitudinal axis held in the cutting guide device, an ultrasound generator which oscillates the cutting edge, a control unit which controls movement of the cutting edge on a cutting path, and a first force measuring device which measures an actual lateral force on the cutting edge transverse to the cutting edge longitudinal axis and transverse to the cutting direction. The first force measuring device sends actual lateral force measurement values to the control unit, which changes at least one cutting parameter based on the measured actual lateral force. A method for using the ultrasonic cutting device is also provided.

A method for processing a workpiece on a numerically controlled machine tool by a tool includes the steps of: controlling a relative movement of the tool relative to the workpiece for processing the workpiece, producing an ultrasonic vibration of the tool by an ultrasonic generator, detecting at least one sensor signal outputted from the ultrasonic generator and identifying a change in the material at the workpiece while controlling the relative movement of the tool relative to the workpiece on the basis of the at least one sensor signal outputted from the ultrasonic generator.

A method of machining ceramic matrix composite components includes providing an ultrasonic vibration tool having a tool tip, and exciting the tool by providing a control current, such that the tool tip is repeatedly vibrated towards and away from a ceramic matrix composite workpiece. A slurry feed is supplied including abrasive particles to a surface to be machined by the tool tip. A vibration amplitude of the tool tip is controlled by sensing load on the tool and communicating with a computing device. The computing device controls the vibration amplitude of the tool tip. The computing device is provided with at least one memory programmed with historic data, and is operable to modify the vibration amplitude signal being sent to the tool, and comparing resulting load levels due to the change in vibration amplitude signals, and storing the change in vibration amplitude signals at the memory.