Error-controlled adaptive machining of aeronautical cabin structures by laser triangulation on-machine measurement

Laser Triangulation On-Machine Measurement (LTOMM) is being implemented increasingly to inspect aeronautical components accurately and efficiently, with its enhanced application in adaptive machining. This work proposes an error compensation and controlling method for measuring the typical features of steps, holes, and freeform surfaces to improve accuracy. Then, the global path to inspect the cabin’s structures is planned by introducing optimization algorithms, thus providing an appropriate sequence to shorten the traveling length. After these, the test piece was designed, measured, and manufactured using the adaptive machining process that integrates the LTOMM. The results show that the measurement errors of steps, holes, and freeform surfaces are +0.0092, −0.006, and +0.0406 mm, respectively, and further reduced to +0.0013, −0.0019, and +0.0083 mm after error controlling. The cabin’s freeform surface was fabricated with the maximum positive and minimum negative errors of +0.184 and −0.123 mm, which is evaluated by the mechanical probe. The measured data-driven machining process can guarantee that the error satisfies the required tolerance, promoting the application of the LTOMM process in aeronautical intelligent manufacturing.