Pocket milling of composite fibre-reinforced polymer using industrial robot

Melo, Ever Grisol de; Klein, Tiago Borsoi; Reinkober, Sascha; Gomes, Jefferson de Oliveira; Uhlmann, Eckart

doi:10.1016/j.procir.2019.09.006

Cited by 9 publications

(4 citation statements)

References 19 publications

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“…In particular, it was important to determine at which cutting speed v c , with what feed per tooth f z and with which tool we get the lowest values of the cutting force components. The lower cutting force is the result of lower cutting 79 N. This is consistent with the research results presented in work [5] and [18], which compared infl uence of the number of cutting edges on cutting forces. In these works it was found that for the analyzed tools with a greater number of cutting edges, the cutting forces were lower compared to a smaller number of cutting edges.…”

Section: Resultssupporting

confidence: 91%

“…On the basis of the obtained results, it was found that lower cutting forces arise at high cutting speeds and high feed (v c = 200 m/min and f = 100 µm/rev) compared to the lower values of cutting speed and feed (v c = 160 m/min and f = 30 µm/rev). Grisol de Melo et al [18] presented the application of industrial robots (IR) in the milling of CFRP composites using various types of tools. They found that the selection of the appropriate tool geometry significantly affects the surface quality after machining and the resultant value of the cutting force F r .…”

Section: Introductionmentioning

confidence: 99%

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Cutting Forces and 3D Surface Analysis of CFRP Milling

Biruk-Urban¹,

Jóźwik²,

Bere³

2022

Adv. Sci. Technol. Res. J.

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Due to the wide application of Carbon Fiber Reinforced Polymer (CFRP) composites in various industries, more and more attention is paid to machining these materials. One of the most popular way of machining composites is the milling. Milling of composite materials (CM) is a diffi cult technology due to their anisotropic and heterogeneous structure and the fact that the reinforcing fi bers have an intense abrasive eff ect on the tool edge during machining. The appropriate selection of technological cutting parameters as well as the type and geometry of the tool can signifi cantly aff ect the value of cutting forces during milling and the quality of the surface after machining. The aim of the paper is to assess the infl uence of used tools (diff ering in the number of cutting edges) and various technological parameters of surface milling of CFRP composites on the cutting forces occurring during machining and on the surface quality after machining. Cutting forces were measured during the milling process on a special stand produced by Kistler and the roughness measurements and surface structure were analyzed using the Alicona Infi niteFocusG5 3D optical microscope. On the basis of performed research it was found that 14 edge tool gives lower values of F x and F y components of the cutting forces comparing to 2 edge tool, which is especially noticeable at higher cutting speed values v c = 160 m/min, where the values of F x and F y components decreased by about 43% at f z = 0.0030 mm/tooth. This tool gives also lower values of the Sa roughness parameter 1.65 µm.

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Section: Resultssupporting

confidence: 91%

Section: Introductionmentioning

confidence: 99%

Cutting Forces and 3D Surface Analysis of CFRP Milling

Biruk-Urban¹,

Jóźwik²,

Bere³

2022

Adv. Sci. Technol. Res. J.

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“…The large-scale structural components like wing ribs, spars, bulkheads, and frames are currently requiring machining processes with large machine tools (Asensio Dominguez et al 2019). Milling processes with an industrial robot are an alternative (de Melo et al 2020) for manufacturing large-scale components of titanium alloys. At the Fraunhofer IPK, test series were carried out with the aim of developing and establishing process principles and parameters for titanium Ti-6Al-4V alloy milling by applying industrial robots.…”

Section: Introductionmentioning

confidence: 99%

Titanium Ti-6Al-4V Alloy Milling by Applying Industrial Robots

Melo

Mohnke

Polte

et al. 2021

UPjeng

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Robotic machining is an alternative to manufacturing processes that combines the technologies of a high-performance machine tool with the flexibility of a 6-axis jointed arm robot. With their large working area, industrial robots are of particular interest for processing large-volume components and large structures, like aircraft components. An influencing variable, which is particularly relevant for milling processes with industrial robots are the cutting force F and the resulting dimensional deviation D. Milling tests of titanium alloys were carried out with an industrial robot and the results compared with a conventional machine tool. Due to the low thermal conductivity and high chemical reactivity of the Ti-6Al-4V alloy, heat is generated and increases the temperature in the contact region of the cutting tool/work piece. That has an impact on the cutting tool wear and increases the cutting force F, and consequently, the dimensional deviation D and the machined surface quality. The aim of the investigations is to find a suitable parameter selection and machining strategy for machining titanium alloys with minimal deviation D and an appropriate surface finish.

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“…Factorial design of experiments has been identified as a very useful tool to evaluate the influence of different factors on precision in robotic machining without having to execute a long and tedious experimental phase. For example, Grisol de Melo, E. et al [35] used a factorial design to evaluate the performance of the industrial robot with respect to the precision of movements in function of the geometry of the tool, feed rate and spindle speed. Previously, Antunes Simões, J.F.C.P.…”

Section: Introductionmentioning

confidence: 99%

A New Approach to the Consideration and Analysis of Critical Factors in Robotic Machining

et al. 2020

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The relative low stiffness of industrial robots is a major limitation on the development of flexible and reconfigurable systems in applications in which process forces and vibration lead into significant tool path deviations with respect to the programmed path as in the case of robotic machining. This paper presents a novel factorial procedure that allows for the preliminary study of the main conditions in robotic machining operations and it determines the critical factors that are affecting the machining path of any robotic cell in order to obtain the process conditions with lower path deviations. In this procedure the most influential robotic machining constraints were identified and classified, the factorial design of experiments was used to enable the execution of the experimental tests and the machining tool path deviation predictive methodology (PREMET) was used to determine the cutting tool path deviation between the programmed and the experimental path as a function of the process variables. Experimental trials have been carried out in order to determine the main factors that affect the robotic machining and influence the main constraints of the process, showing a reduction greater than a 36% of the cutting tool path deviation in groove milling of aluminum. The critical factors identified in order of importance are: hardness of the material, location of the workpiece, orientation of milling head relative to working direction and cutting conditions. This procedure can be extended to future factorial studies to improve the precision of robotic machining (in operations such as face milling, contouring, pocketing) and to establish design criteria for machining robotic cells.

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Pocket milling of composite fibre-reinforced polymer using industrial robot

Cited by 9 publications

References 19 publications

Cutting Forces and 3D Surface Analysis of CFRP Milling

Cutting Forces and 3D Surface Analysis of CFRP Milling

Titanium Ti-6Al-4V Alloy Milling by Applying Industrial Robots

A New Approach to the Consideration and Analysis of Critical Factors in Robotic Machining

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