Control feedback loop for real-time variable needle peen forming

A method for processing and forming a contour for a metal workpiece, wherein the workpiece has a surface, the method comprising the steps of:

• establishing predetermined processing parameters for achieving the contour for the workpiece;
• providing a controller;
• installing the predetermined processing parameters in the controller;
• positioning the workpiece for processing until the workpiece has achieved the contour;
• providing an end effector and a driven member mounted on the end effector;
• communicating with the controller to the end effector with the predetermined processing parameters;
• impacting the surface of a first section of the workpiece multiple times with the driven member under the control of the predetermined processing parameters for achieving the contour of the workpiece;
• providing a sensor for monitoring existing physical conditions of a second upcoming section of the workpiece during impacting;
• providing a manipulator for communicating with the controller for locating and moving the end effector and driven member through a predetermined motion path under the control of the predetermined processing parameters;
• and
• adjusting the predetermined processing parameters into adjusted processing parameters in reaction to existing physical conditions of the second upcoming section of the workpiece received from the sensor for further processing of the second upcoming section of the workpiece with the adjusted processing parameters for achieving a contour for the second upcoming section of the workpiece.

Apparatus for processing a metal workpiece to a metal component, wherein the workpiece has a surface, the apparatus comprising:

• a support for the workpiece during the processing;
• a driven member for applying multiple impacts to the surface of the workpiece;
• a controller having predetermined processing parameters connected to the driven member for applying multiple impacts against the surface of a first section of the workpiece under the control of the predetermined processing parameters for changing physical characteristics of the metal workpiece;
• a sensor for continuously sensing existing physical conditions of a second upcoming section of the workpiece while the driven member is applying multiple impacts to the first section of the workpiece;
• and
• a feedback system for transmitting existing physical conditions of the second upcoming section of the workpiece from the sensor to the controller for adjusting the predetermined processing parameters into adjusted processing parameters in reaction to the existing physical conditions of the second upcoming section of the workpiece for further processing for achieving the metal component.