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Near-net-shape components are popular among the aerospace industry for low material waste and high manufacturing efficiency. However, it is difficult to machine such components into final shapes because the machining allowance is often distributed unevenly and even insufficient. This paper proposed a novel system for adaptive machining near-net-shape components, which integrates units like on-machine measurement based on probe and ultrasonic-sensor, machining allowance constrained localization, tolerance range constrained shape reconstruction, and TCP (tool cutter position) template-based NC programming. Firstly, localization and free form deformation (FFD)-based shape construction are performed within the tolerance ranges of the component, and an even distribution of the machining allowance can be obtained. Next, the quick NC programming that directly manipulates the TCPs by using spatial deformation is introduced. Last, the data transmission between units is illustrated. A case study of the machining titanium turbine blade is performed, which validates the proposed system.
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