Systems and methods for automated adaptive manufacturing of airfoil castings

A system comprising:

• a processor;
• and
• a tangible, non-transitory memory configured to communicate with the processor,
• the tangible, non-transitory memory having instructions stored thereon that, in response to execution by the processor, cause the processor to perform operations comprising:
• receiving, by the processor, a three dimensional scan of a work piece;
• generating, by the processor, a conformal-mapped nominal model of the work piece based on the three dimensional scan and a conformal-mapping model, wherein the conformal-mapped nominal model is generated using a machine learning technique;
• comparing, by the processor, the three dimensional scan to a digital model of the work piece, the comparing further comprising:
• comparing, by the processor, the conformal-mapped nominal model with the three dimensional scan;
• and
• generating, by the processor, a difference map based on the comparison;
• identifying, by the processor, an area of dimensional abnormality on the work piece based on the comparison, the identifying further comprising:
• classifying, by the processor, the difference map into a positive feature set and a negative feature set;
• matching, by the processor, the positive feature set and the negative feature set against an index of features to generate a matched feature set;
• and
• instructing, by the processor, a computer numerical control tool system to alter the area of dimensional abnormality on the work piece.

An article of manufacture including a non-transitory, tangible computer readable storage medium having instructions stored thereon that, in response to execution by a computer based system, cause the computer based system to perform operations comprising:

• receiving, by a computer based system, a three dimensional scan of a work piece;
• generating, by the computer based system, a conformal-mapped nominal model of the work piece based on the three dimensional scan and a conformal-mapping model, wherein the conformal-mapped nominal model is generated using a machine learning technique;
• comparing, by the computer based system, the three dimensional scan to a digital model of the work piece, the comparing further comprising:
• comparing, by the computer based system, the conformal-mapped nominal model with the three dimensional scan;
• and
• generating, by the computer based system, a difference map based on the comparison;
• identifying, by the computer based system, an area of dimensional abnormality on the work piece based on the comparison, the identifying further comprising:
• classifying, by the computer based system, the difference map into a positive feature set and a negative feature set and
• matching, by the computer based system, the positive feature set and the negative feature set against an index of features to generate a matched feature set;
• and
• instructing, by the computer based system, a computer numerical control tool system to alter the area of dimensional abnormality on the work piece.