System and method for machining a workpiece installed on a rotary table

A method for machining a workpiece installed on a rotary table to form an aircraft engine component, the method comprising:

• positioning the workpiece on the rotary table;
• identifying a first position and a first orientation for at least one point on one or more surfaces of the workpiece using at least one dimensional measurement sensor;
• determining a first machine-workpiece vector and a first rotation-workpiece vector for the at least one point;
• and
• machining the workpiece at a plurality of circumferential positions by, for each circumferential position of the plurality of circumferential positions, sequentially:
• rotating the workpiece with the rotary table about a rotational axis by a rotation angle to one circumferential position of the plurality of circumferential positions;
• calculating a second position and a second orientation for the at least one point by rotating the first orientation about the rotational axis by the rotation angle to calculate the second orientation, rotating the first rotation-workpiece vector about the rotational axis by the rotation angle to calculate a second rotation-workpiece vector, and determining a second machine-workpiece vector using the second rotation-workpiece vector to calculate the second position;
• updating a workpiece position and a workpiece orientation for the workpiece using the second position and the second orientation for the at least one point;
• and
• machining the workpiece at the one circumferential position with a machining assembly using the updated workpiece position and updated workpiece orientation.

A machining system for machining a workpiece to form an aircraft engine component, the machining system comprising:

• a machining assembly;
• rotary table including a rotatable platform configured for rotation about a rotational axis;
• the workpiece positioned on the rotatable platform, the workpiece has a centerline axis, and the workpiece is positioned on the rotary table with the centerline axis offset from the rotational axis;
• a dimensional measurement assembly including a touch probe;
• and
• a controller including a processor in communication with a non-transitory memory storing instructions including computer numerical control (CNC) instructions, which instructions when executed by the processor, cause the processor to:
• control the dimensional measurement assembly to identify a first position and a first orientation for at least one point on one or more surfaces of the workpiece with the touch probe;
• determine a first machine-workpiece vector and a first rotation-workpiece vector for the at least one point;
• and
• machine the workpiece at a plurality of circumferential positions by, for each circumferential position of the plurality of circumferential positions, sequentially:
• controlling the rotary table to rotate the workpiece about the rotational axis by a rotation angle to one circumferential position of the plurality of circumferential positions;
• determining a second position and a second orientation for each point of the at least one point with the workpiece in the one circumferential position;
• updating a workpiece position and a workpiece orientation in a coordinate system for the workpiece using the second position and the second orientation;
• and
• controlling the machining assembly to machine the workpiece using the updated workpiece position and updated workpiece orientation.