Postprocessor for Verification of Robot Movements with Additional Axis after Toolpath Optimization

The use of industrial robots for machining operations is pursued by industry lately, since they can increase the flexibility of the production system and reduce production costs. However, their industrial adoption is still limited, mainly due to their insufficient structural stiffness and posture-dependent dynamic behavior, leading to limited machining process accuracy. For this purpose, the Digital-Model of a machining robot has been developed, providing a tool for virtual commissioning of the process that can be used during the process planning stage. The Multi-Body Simulation method combined with a Component Mode Synthesis have been adopted, considering flexibility of both the joints and links. On top of that, and motivated from robotic-based machining systems’ flexibility and versatility, two optimization algorithms have been developed, attempting to increase the process accuracy. A workpiece placement optimization algorithm, attempting to maximize the robot stiffness during the process acquiring knowledge from the robot stiffness maps, and a feed-rate scheduling algorithm, attempting to constrain the contour error by regulating the generated cutting forces. The capabilities and functionality of the developed model and optimization algorithms are showcased in two different case studies, with the results proving the improvements on the process accuracy after the application of the optimization algorithms. Finally, an experimental validation of the Digital-Model has been performed, to confirm the consistency between model outputs and real experimental data.

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Research on the Entrance Damage of Carbon Fiber-Reinforced Polymer/Ti6Al4V Stacks in Six-Degrees-of-Freedom Robot Drilling

Zhong,

Zhang,

Wang

et al. 2024

Machines

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Carbon fiber-reinforced polymer (CFRP)/titanium alloy (Ti6Al4V) stacks are widely used in the aerospace industry due to their excellent physical properties. The substantial demand for drilling components in the aerospace industry necessitates the implementation of enhanced processing efficiency and drilling quality standards. Six-degrees-of-freedom robots are commonly used in the aerospace industry due to their high production efficiency, high flexibility, and low labor costs. However, due to the weak stiffness, chatter is prone to occur during processing, which has a detrimental impact on the quality of the finished product. As an advanced processing technology, ultrasonic-assisted machining technology can effectively reduce the cutting force and suppress the chatter in the drilling process, so it is widely used in production. In this paper, first, the robot kinematic (dexterity) and stiffness performance is analyzed. Then, the appropriate range of the machining plane and the posture of the robot in the workspace are selected. Finally, the vibration and CFRP entrance damage during the machining process are compared and studied in conventional robotic drilling (CRD) and ultrasonic-assisted robotic drilling (UARD). The experimental results demonstrate that the UARD is an effective method for reducing vibration during the machining process. Compared with the CRD, the CFRP entrance delamination damage in UARD is reduced. Under the appropriate processing parameters, the entrance delamination factor could be reduced by 15%, and the burr height could be reduced by 45%. Obviously, the UARD is a promising process to improve the CFRP entrance delamination damage.

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Postprocessor for Verification of Robot Movements with Additional Axis after Toolpath Optimization

Cited by 3 publications

References 8 publications

An advanced machining robot flexible programming methodology supported by verification in a virtual environment

An advanced machining robot flexible programming methodology supported by verification in a virtual environment

On the Optimization of Robot Machining: A Simulation-Based Process Planning Approach

Research on the Entrance Damage of Carbon Fiber-Reinforced Polymer/Ti6Al4V Stacks in Six-Degrees-of-Freedom Robot Drilling

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