The Boeing Company

Jared Lee Bolin

Ryan Lee Hanks

Eric Joseph Stern

Philip Lawrence Freeman

James B Castle

Sebastian Nervi

Samuel Joseph Easley

Randolph B Hancock

Christopher Tyler

A method includes providing a frame sheet. The method also includes elevating a temperature of the frame sheet to at or above an elevated target temperature. Further the method includes, at or above the elevated target temperature, forming the frame sheet to provide a frame defining a web and at least one flange. Also, the method includes machining at least one of the web or the at least one flange to reduce a thickness of the at least one of the web or the at least on flange.

Methods of manufacture for aircraft substructure

Provided is a machine system having optical endpoint control and associated method for maintaining having is provided constant optical contact. Specifically, the machine system comprises a machine capable of movement in at least one direction. The machine is configured such that, during a calibration phase, a steerable retroreflective system is mounted upon the machine for movement therewith. A controller is configured to control the movement of the machine in at least one direction. The machine system may be configured to automatically adjust the feedrate of the machine, upon determining that a velocity required for the positioner to move the retroreflector to a desired position exceeds a certain segment feedrate threshold, such that an incident beam of light can maintain constant contact with the retroreflector throughout movement of the machine from the first position to the second position.

Machine system and associated method for optical endpoint control optimization

A system and method are provided for estimating initial stresses in and eigenstrains of a material. The system may receive measured geometric data including measurements of a material before and after the application of a manufacturing process thereto. The measurements may indicate a residual stress in a coupon after application of the manufacturing process. Estimated linear elastic strains may be calculated in respective opposing sides of the coupon based on the measured geometric data. A linear elastic reaction of the material to the manufacturing process may be calculated based at least in part on the estimated linear elastic strains. The system may then calculate an estimated initial stress in the material as a sum of the residual stress in the coupon and the linear elastic reaction of the material, and calculate an estimated eigenstrain of the material based at least in part on the estimated initial stress in the material.

Initial stress and eigenstrain computation system and method

Rough machining of a workpiece is performed by a numerically controlled machine tool using an adaptive toolpath technique. Material removal rate and machine efficiency are increased by forming a pre-roughing slot in the workpiece along medial axes, and machining the remainder of the workpiece using a toolpath that begins inside the pre-roughing slot and spirals outwardly in smooth curves.

Method of optimizing toolpaths using medial axis transformation

A method and apparatus may be provided for performing an operation on a workpiece. A tool holder with a tool and the workpiece may be positioned relative to each other. The tool holder may be attached to a machine. The tool may have a sleeve and a number of cutting features. The sleeve may have a first end, a second end, a surface, and a channel with an opening at the first end of the sleeve and an opening at the second end of the sleeve. The sleeve may receive at least a portion of a rod for the tool holder in the channel. A stiffness of the sleeve may be greater than a stiffness of the tool holder. The number of cutting features may be associated with the surface of the sleeve. The operation may be performed using the tool holder with the tool on the workpiece.

Cutting tool sleeve for tool holders

A method and apparatus may be present for performing an operation on a workpiece. A tool holder with a sleeve and workpiece may be positioned relative to each other. The rod tool holder may be attached to a machine and may have a first stiffness. The sleeve may have a channel and a second stiffness. The channel may be configured to receive at least a portion of the rod. The operation may be performed using the rod with the tool on the workpiece.

Stiffening sleeve for tool holders

A method and apparatus for managing machining. A desired level of engagement of a tool may be identified with a workpiece. A tool path for the tool may be generated relative to the workpiece. The tool path may have a number of levels of engagement of the tool with the workpiece along the tool path. The number of levels of engagement of the tool with the workpiece along the tool path may be based on the desired level of engagement.

Tool path generation for machining operations

A method of predicting distortion in a workpiece may include measuring residual stress induced in a coupon surface of a plate coupon by a selected manufacturing operation. The induced residual stress measurements may be fitted to a curve shape function. A moment coefficient may be calculated based upon the fitted induced residual stress measurements. The moment coefficient may be used to calibrate a stress function and corresponding stress magnitude. The calibrated stress function may be applied to a model of the workpiece such that the distortion of the workpiece may be predicted.

Stress function calibration method

Techniques and apparatuses to provide vibration reduction of a workpiece when performing machining operations are disclosed. In various embodiments, a machine tool includes a shank having at least one end configured for engagement with a machine operable to rotate the shank. A cutting portion has a diameter defined by features used to remove material from a workpiece. The cutting portion is coupled to the shank. A vibration reduction dampener may be located between the shank and the workpiece.

Workpiece vibration reduction

A cutting tool includes a tool body having proximal and distal ends and defining a central axis. The tool body includes a shank portion and a fluted portion. The shank portion may be configured to be rotatably engageable to a milling machine. The fluted portion may include a plurality of teeth disposed about a circumference thereof and being formed at a radius relative to the central axis. In one embodiment, the teeth may be divided into first and second tooth sections with the teeth in the second tooth section being formed at a reduced radius relative to the teeth in the first tooth section.

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Millstadt, IL, United States of America

Jared Lee Bolin