scholarly journals Optimization of an autonomous robotic drilling system for the machining of aluminum aerospace alloys

2021 ◽  
Author(s):  
Benjamin Pereira ◽  
Christian Andrew Griffiths ◽  
Benjamin Birch ◽  
Andrew Rees
Keyword(s):  
High Speed ◽  
Industrial Robot ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Cnc Milling Machine ◽  
Aerospace Alloys ◽  
Machine Spindle ◽  
Drilling System ◽  
Condition Monitoring System ◽  
Exit Burr

AbstractThis paper aims to identify the capability of a highly flexible industrial robot modified with a high-speed machine spindle for drilling of aluminum 6061-T6. With a focus on drilling feed rate, spindle speed, and pecking cycle, the hole surface roughness and exit burr heights were investigated using the Taguchi design methodology. A state of the art condition monitoring system was used to identify the vibrations experienced during drilling operation and to establish which robot pose had increased stiffness, and thus the optimum workspace for drilling. When benchmarked against a CNC machine the results show that the CNC was capable of producing the best surface finish and the lowest burr heights. However, the robot system matched and outperformed the CNC in several experiments and there is much scope for further optimization of the process. By identifying the optimum pose for drilling together with the idealized settings, the proposed drilling system is shown to be far more flexible than a CNC milling machine and when considering the optimized drilling of aerospace aluminum this robotic solution has the potential to drastically improve productivity.

scholarly journals Optimization of an Autonomous robotic drilling system for the Machining of Aluminum Aerospace Alloys

2021 ◽  
Author(s):  
Benjamin Pereira ◽  
Christian Andrew Griffiths ◽  
Benjamin Birch ◽  
Andrew Rees
Keyword(s):  
High Speed ◽  
Industrial Robot ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Cnc Milling Machine ◽  
Aerospace Alloys ◽  
Machine Spindle ◽  
Drilling System ◽  
Condition Monitoring System ◽  
Exit Burr

Abstract This paper aims to identify the capability of a highly flexible industrial robot modified with a high-speed machine spindle for drilling of Aluminum 6061-T6. With a focus on drilling feedrate, spindle speed and pecking cycle, the hole surface roughness and exit burr heights were investigated using the Taguchi design methodology. A state of the art condition monitoring system was used to identify the vibrations experienced during drilling operation and to establish which robot pose had increased stiffness, and thus the optimum workspace for drilling. When benchmarked against a CNC machine the results show that the CNC was capable of producing the best surface finish and the lowest burr heights. However, the robot system matched and outperformed the CNC in several experiments and there is much scope for further optimization of the process. Overall the proposed drilling system is far more flexible than a CNC milling machine and when considering the optimized drilling of aerospace aluminum this robotic solution has the potential to drastically improve productivity.

scholarly journals Modular fastening system and tool–holder working unit for incremental forming

2019 ◽  
Vol 299 ◽  
pp. 05005
Author(s):  
Melania Tera ◽  
Claudia–Emilia Gîrjob ◽  
Cristina–Maria Biriș ◽  
Mihai Crenganiș
Keyword(s):  
Machine Tools ◽  
Incremental Forming ◽  
Industrial Robot ◽  
Industrial Robots ◽  
Cnc Milling ◽  
End Effector ◽  
Tool Holder ◽  
Cnc Milling Machine ◽  
Milling Machines ◽  
Sheet Metal Workpiece

Incremental forming can be usually unfolded either on CNC milling machine–tools or serial industrial robots. The approach proposed in this paper tackles the problem of designing a modular fastening system, which can be adapted for both above mentioned technological equipment. The fastening system of the sheet–metal workpiece is composed of a fixing plate and a retaining plate. The fixing and retaining plates will be made up of different individual elements, which can be easily repositioned to obtain different sizes of the part. Moreover, the fastening system has to be able to be positioned either horizontally (to be fitted on CNC milling machines) or vertically (to be fitted on industrial robots. The paper also presents the design of a tool–holder working unit which will be fitted on KUKA KR 210 industrial robot. The working unit will be mounted as end–effector of the robot and will bear the punch, driving it on the processing toolpaths.

CREATING HOLES IN SOUND-ABSORBING STRUCTURES DURING MOLDING

2020 ◽  
pp. 93-101
Author(s):  
V.S. Dyshenko ◽  
◽  
M.I. Minibaev ◽  
M.N. Usacheva ◽  
◽  
...  
Keyword(s):  
Tensile Strength ◽  
Carbon Fiber ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Special Equipment ◽  
Cnc Milling Machine

Monolithic samples are made of carbon fiber based on fabrics that are cured by infusion. Perforation is carried out on a CNC milling machine after confirmation and on special equipment until confirmation. Samples are cut from the plate at an angle of 4–5°, as the orientation of the holes in real sound-absorbing structures. Samples tested for tensile strength according to GOST 56785–2015. Samples cut from plates made by molding give 25% higher results than samples obtained by processing on a CNC machine.

Study on Intelligent Control of Milling Process Based on MATLAB

2011 ◽  
Vol 328-330 ◽  
pp. 1759-1762
Author(s):  
Xing Yu Lai ◽  
Chun Yan Yan ◽  
Bang Yan Ye ◽  
Wei Guang Li
Keyword(s):  
Intelligent Control ◽  
Milling Process ◽  
Depth Of Cut ◽  
Cnc Machine Tool ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Experimental Platform ◽  
Simulink Model ◽  
Cnc Milling Machine ◽  
Constant Cutting Force

In order to achieve the intelligent control of milling process, an experimental platform is constructed in XK5140 CNC machine tool. The control system is based on the Simulink model of MATLAB and the controller is established by programming S-function. The experiments are performed on steel workpiece with variable depth of cut by controlling milling force. The experimental results show that the intelligent control of the milling process is feasible using this experimental platform. The proposed controller can adaptively adjust the feed rate till achieving a constant cutting force approaching the set point in varied cutting conditions. CNC milling machine can make full use of its manufacturing capacity when processing the parts, thus improving the cutting efficiency and protecting the tool.

scholarly journals The Mechanical Properties Analysis of Machine Tool Spindle After Remanufacturing Based on Uncertain Constraints

2015 ◽  
Vol 9 (1) ◽  
pp. 150-155 ◽  
Author(s):  
Ling Liu
Keyword(s):  
High Speed ◽  
Dynamic Performance ◽  
Beam Theory ◽  
Optimized Design ◽  
Cnc Machine ◽  
Element Analysis ◽  
Heavy Load ◽  
Spindle System ◽  
Machine Spindle ◽  
The Cost

In this paper, the CNC machine spindle after remanufacturing is researched as an object on uncertain constraints. At first, the equations of the machine spindle motion based on beam theory are established. This article uses Finite Element Analysis (FEA) function to analyze the remanufacturing of machine spindle system in the free mode and while static and the actual working conditions of multi-modal analysis of the spindle’s constraints state. By analysis it is known that the spindle vibrates and deforms at high speeds, and some assumptions are used to improve the unreasonable parameters, so that the spindle’s dynamic performance is more stable and reliable in the conditions of the high speed and heavy load operation. In addition, simplifying the cost and shortening the design cycle are the part of the analysis. The results provides an optimized design and a basis for precision control for the heavy-duty mechanical spindle system or machine spindle system.

Non-Contact Device for Measuring Frequency Response Functions of CNC Machine Tools

Manufacturing ◽  
2003 ◽  
Author(s):  
Donald Esterling ◽  
F. Donald Caulfield ◽  
Aaron Kiefer ◽  
Gregory Buckner ◽  
Pavan Jaju
Keyword(s):  
Frequency Response ◽  
Machine Tools ◽  
High Speed ◽  
Operating Conditions ◽  
Modal Testing ◽  
Cnc Machine Tools ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Machining Processes ◽  
Test Procedures

The frequency response function (FRF) of a CNC machine tool is composed of tool/toolholder/spindle dynamics, and plays an important role in determining the stability of high speed machining processes. This paper details the design, development and operational verification of a non-contacting, controllable, electromechanical actuator (EMA) for measuring the FRFs of tools mounted in CNC milling machines. Although standard modal testing methods are available and provide similarly accurate results, these test procedures are difficult to perform in machine shop environments and can require expensive equipment. The EMA developed as part of this research extends the capabilities of the NIST “best speeds device” to provide controllable, non-contacting excitation for modal tests on machine tools. This EMA device offers the advantages of being accurate, easy to use, and applicable to a wide variety of tools and operating conditions.

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