Adaptive path generation for CNC machining

A method for adapting a machine tool path to an actual part shape, said method comprising:

• providing a nominal tool path defining a machining operation on a surface of a nominal workpiece;
• defining a grid of nominal feature points, where each of the nominal feature points lies on the surface of the nominal workpiece, and the grid of nominal feature points covers an area encompassing the nominal tool path;
• providing a new workpiece;
• measuring a grid of actual feature points on the new workpiece using a probe, where each of the actual feature points is measured by the probe by approaching a location of a corresponding nominal feature point in a direction normal to a local surface tangent plane, where the local surface tangent plane is determined from adjacent points in the grid of nominal feature points;
• constructing a space mapping function, using a computer having a processor and memory, where the space mapping function defines a spatial transformation from the grid of nominal feature points to the grid of actual feature points;
• and
• computing a new tool path, using the computer, by applying the space mapping function to the nominal tool path.