In production and manufacturing engineering, some redesign, distorted or worn parts cannot be milled according to their original CAD geometries due to the existed shape deviations. Generating CAM data in traditional manner for each individual part is time-consuming and labor intensive. This paper proposes a quick and convenient adaptive approach for machining distorted hollow blade, in which a template CAM data is spatially deformed according to some measured points from actual shape. The actual shape of the part was firstly inspected by on-machine measurement method. The measured points data was matched to the original nominal CAD geometry with ICP algorithm afterwards, by which the point-pairs between the measurement points and their corresponding points were established. Based on the distance deviations between these point-pairs, global and local modifying methods of template CAM data were developed using spatial deformation. By embedding the template CAM data in the calculated deformation volume, a new CAM data was achieved. Finally, a series of measurement and machining tests were performed, which validates the feasibility of proposed adaptive machining approach in this paper.

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