Report of Robotic Machining Measurements Using a Stäubli TX200 Robot: Application to Milling

2017 ◽  
Author(s):  
Hoai Nam Huynh ◽  
Edouard Rivière-Lorphèvre ◽  
Olivier Verlinden
Keyword(s):  
Cutting Forces ◽  
Industrial Robot ◽  
Machining Process ◽  
Force Model ◽  
Robot Arm ◽  
Robotic Machining ◽  
Depth Analysis ◽  
Set Up ◽  
Manufacturing Technologies ◽  
The Impact

One of the most promising manufacturing technologies nowadays is certainly the material removal using an industrial robot. Robotic machining is a fast growing technology as the number of robots used in industry is increasing continuously. Robots are indeed flexible which allows them to deal with large workpieces. On the other hand, their low stiffness restricts their use to machining operations accommodating a low accuracy or involving limited cutting forces as milling instabilities are more likely to occur. Since the impact of the machining process on the robot structure is not fully understood at this time, this paper aims to provide an in-depth analysis of experimental data obtained while machining an aluminium plate with a Stäubli robot arm. After describing the experimental set-up, three different analyses (metrological, vibration, cutting forces) were carried out on the basis of the machined workpiece and the measured signals. An identification of the cutting coefficients was eventually performed in order to fit a cutting force model to the measurements. Simulation results showed a good correlation with the experimental measurements.

An Implementation of Analytical Boundary Simulation on Feedrate Scheduling during Semi-Finish Milling

2016 ◽  
Vol 851 ◽  
pp. 211-215
Author(s):  
Hendriko Hendriko
Keyword(s):  
Cutting Forces ◽  
Machining Process ◽  
Depth Of Cut ◽  
Force Model ◽  
Cutting Force Model ◽  
Feedrate Scheduling ◽  
Helical Angle ◽  
Result Show ◽  
Five Axis ◽  
Good Agreement

In five-axis milling, determining the continuously changing Cutter Workpiece Engagement (CWE) remains a challenge. All the feedrate calculation method that have been reported need a precise information about Cutter Workpiece Engagement. In this paper, the cut geometry was calculated using an analytical method called Analytical Boundary Simulation (ABS). This method was reported accurate and less expensive in term of calculation time. The cut geometry data was then used to calculate the instantaneous cutting forces. A new mechanistic force model was developed by taken into account the variation of axial depth of cut, the feedrate, the tool orientation, and the helical angle. Analytical boundary simulation and mechanisitic cutting force model were then used to optimize a semi finish machining process using feedrate scheduling. The applicability of the proposed method was verified experimentally and the result show that the calculated cutting forces of feedrate scheduling have a good agreement with those obtained from the experimental work.

scholarly journals Large Field Alpha Irradiation Setup for Radiobiological Experiments

2019 ◽  
Vol 2 (3) ◽  
pp. 75 ◽  
Author(s):  
Roobol ◽  
Kouwenberg ◽  
Denkova ◽  
Kanaar ◽  
Essers
Keyword(s):  
Alpha Particle ◽  
Super Resolution ◽  
Cellular Level ◽  
Alpha Particles ◽  
Large Field ◽  
Directed Movement ◽  
Particle Irradiation ◽  
Depth Analysis ◽  
Set Up ◽  
The Impact

The use of alpha particles irradiation in clinical practice has gained interest in the past years, for example with the advance of radionuclide therapy. The lack of affordable and easily accessible irradiation systems to study the cell biological impact of alpha particles hampers broad investigation. Here we present a novel alpha particle irradiation set-up for uniform irradiation of cell cultures. By combining a small alpha emitting source and a computer-directed movement stage, we established a new alpha particle irradiation method allowing more advanced biological assays, including large-field local alpha particle irradiation and cell survival assays. In addition, this protocol uses cell culture on glass cover-slips which allows more advanced microscopy, such as super-resolution imaging, for in-depth analysis of the DNA damage caused by alpha particles. This novel irradiation set-up provides the possibility to perform reproducible, uniform and directed alpha particle irradiation to investigate the impact of alpha radiation on the cellular level.

Calibration of a Milling Force Model Using Feed and Spindle Power Sensors

2008 ◽  
Author(s):  
Bryan Javorek ◽  
Barry K. Fussell ◽  
Robert B. Jerard
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Machining Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Drive Power ◽  
Average Force ◽  
Force Monitoring ◽  
Milling Force Model

Changes in cutting forces during a milling operation can be associated with tool wear and breakage. Accurate monitoring of these cutting forces is an important step towards the automation of the machining process. However, direct force sensors, such as dynamometers, are not practical for industry application due to high costs, unwanted compliance, and workspace limitations. This paper describes a method in which power sensors on the feed and spindle motors are used to generate coefficients for a cutting force model. The resulting model accurately predicts the X and Y cutting forces observed in several simple end-milling tests, and should be capable of estimating both the peak and average force for a given cut geometry. In this work, a dynamometer is used to calibrate the feed drive power sensor and to measure experimental cutting forces for verification of the cutting force model. Measurement of the average x-axis cutting forces is currently presented as an off-line procedure performed on a sacrificial block of material. The potential development of a continuous, real-time force monitoring system is discussed.

Machinability Evaluation of Difficult-to-Cut Materials Based on Variable Processing Cost per Unit Material

2011 ◽  
Vol 418-420 ◽  
pp. 1900-1905
Author(s):  
Xun Li ◽  
Jian Ting Wu
Keyword(s):  
Evaluation System ◽  
Cutting Parameters ◽  
Parameters Optimization ◽  
Machining Process ◽  
Cutting Mechanism ◽  
Processing Cost ◽  
Depth Analysis ◽  
Cutting Parameters Optimization ◽  
The Impact ◽  
Variable Processing

Cutting mechanism and characteristics of difficult-to-cut materials have a great difference. Currently, systems or indicators of the machinability are so many that we do not know how to utilize them. Not only because there is no consideration the impact of cutting conditions and parameters on machinability, but they are not be accurate quantitative responses to the machinability of workpiece materials, especially to the difficult-to-cut materials. Based on in-depth analysis of cutting mechanism and objective functions of cutting parameters optimization, an innovative machinability evaluation system based on the variable processing cost per unit material is developed. And the economics of machining process are introduced to the machinability evaluation system. Several classic analysises and calculation examples of the machinability of several typical difficult-to-cut materials have been presented at the end of paper to give a clear picture from the application of the system. The result demonstrates that the machinability evaluation system based on the variable processing cost per unit material has good practicability and maneuverability.

scholarly journals Modeling and optimization of cutting forces and effect of turning parameters on SiCp/Al 45% vs SiCp/Al 50% metal matrix composites: a comparative study

2021 ◽  
Vol 3 (7) ◽  
Author(s):  
Rashid Ali Laghari ◽  
Jianguang Li
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Positive Response ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Force Model ◽  
Sic Particles

Abstract In this study, the proposed experimental and second-order model for the cutting forces were developed through several parameters, including cutting speed, feed rate, depth of cut, and two varying content of SiCp. Cutting force model was developed and optimized through RSM and compared for two different percentages of components SiCp/Al 45% and SiCp/Al 50%. ANOVA is used for Quantitative evaluation, the main effects plot along with the evaluation using different graphs and plots including residual analysis, contour plots, and desirability functions for cutting forces optimization. It provides the finding for choosing proper parameters for the machining process. The plots show that during increment with depth of cut in proportion with feed rate are able to cause increments in cutting forces. Higher cutting speed shows a positive response in both the weight percentage of SiCp by reducing the cutting force because of higher cutting speed increases. A very fractional increasing trend of cutting force was observed with increasing SiCp weight percentages. Both of the methods such as experiment and model-predicted results of SiCp/Al MMC materials were thoroughly evaluated for analyzing cutting forces of SiCp/Al 45%, and SiCp/Al 50%, as well as calculated the error percentages also found in an acceptable range with minimal error percentages. Article Highlights This study focuses on the effect of cutting parameters as well as different percentage of SiC particles on the cutting forces, while comparing the results of both SiC particles such as SiCp/Al 45%, and SiCp/Al 50% the result shows that there isn’t fractional amount of impact on the cutting force with nominal increasing percentages of SiC particles. Cutting speed in machining process of SiCp/Al shows positive response in reducing the cutting forces, however, increasing amount of depth of cut followed by increasing feed rate creates fluctuations in cutting force and thus increases the cutting force in the cutting process. The developed RSM mathematical model which is based on the box Behnken design show excellent competence for predicting and suggesting the machining parameters for both SiCp/Al 45%, and SiCp/Al 50% and the RSM mathematical model is feasible for optimization of the machining process with good agreement to experimental values.

Modeling and Simulation of Robotic Material Removal Process in Uncertainty Environment

2011 ◽  
Vol 675-677 ◽  
pp. 1003-1006
Author(s):  
Xian Lun Wang ◽  
Yu Xia Cui
Keyword(s):  
Material Removal ◽  
Fuzzy Controller ◽  
Fuzzy Rule ◽  
Interaction Force ◽  
Machining Process ◽  
Force Model ◽  
Removal Process ◽  
Robotic Machining ◽  
On Line ◽  
Uncertainty Environment

The interaction force and the environments uncertainties are the most challenges for robotic material removal process. The conventional constant force control methods for the deburring process have the inherent characteristic of leaving the deburred surface as an imprint of the original. A process force model considering the burrs variation is presented to predict the contact force in robotic machining process. A self-tuning fuzzy strategy is adopted to implement the on-line compensation for the static error caused by the traditional impedance controller. The fuzzy controller is adjusted by an updating factor to select the most appropriate fuzzy rule set based on the measured performance results. Simulation results show efficacy of the proposed method in robotic machining process, and the control performance is better than that of a traditional impedance controller.

scholarly journals Robotic High Speed Machining of Aluminum Alloys

2011 ◽  
Vol 188 ◽  
pp. 584-589 ◽  
Author(s):  
Imed Zaghbani ◽  
M. Lamraoui ◽  
V. Songmene ◽  
M. Thomas ◽  
M. El Badaoui
Keyword(s):  
Stability Criterion ◽  
High Speed ◽  
Spindle Speed ◽  
Machining Process ◽  
Robotic Machining ◽  
Machined Parts ◽  
Machining System ◽  
Using Data ◽  
Manufacturing Technologies ◽  
High Level

The robotic machining is one of the most versatile manufacturing technologies. Its emerging helped to reduce the machining cost of complex parts. However, its application is sometimes limited due to the low rigidity of the robot. This low stiffness leads to high level of vibrations that limit the quality and the precision of the machined parts. In the present study, the vibration response of a robotic machining system was investigated. To do so, a new method based on the variation of spindle speed was introduced for machining operation and a new process stability criterion (CS) based on acceleration energy distribution and force signal was proposed for analysis. With the proposed method the vibrations and the cutting force signals were collected and analyzed to find a reliable dynamic stability machining domain. The proposed criterion and method were validated using data obtained during high speed robotic machining of 7075-T6 blocks. It was found that the ratio of the periodic energy on the total energy (either vibrations or cutting forces) is a good indicator for defining the degree of stability of the machining process. Besides, it was observed that the spindle speed with the highest ratio stability criterion is the one that has the highest probability to generate the best surface finish. The proposed method is rapid and permits to avoid trial-error tests during robot programming.

High Velocity Compaction : Overview of Materials, Applications and Potential

2007 ◽  
Vol 534-536 ◽  
pp. 293-296 ◽  
Author(s):  
Florence Dore ◽  
Ludovic Lazzarotto ◽  
Stephane Bourdin
Keyword(s):  
Impact Velocity ◽  
High Velocity ◽  
New Technology ◽  
Machining Process ◽  
Powder Materials ◽  
Component Shape ◽  
High Velocity Compaction ◽  
Set Up ◽  
The Impact ◽  
Sintered Materials

Since 2000, CETIM has been equipped with a High Velocity Press that can deliver up to 5 shots per second with each blow accurately set up (up to 20000J) thanks to the impact velocity regulation (up to 11m.s-1). Through different projects, CETIM and its scientific and industrial partners have evaluated the potential of this new technology in terms of materials and component shape. Various kinds of powder materials were studied: metals, ceramics and polymers. The HVC process was used with success to manufacture gears, large parts and multilevel components. More than, the green machining process that enables shapes to be produced that would otherwise be impossible to compact is improved by the high density of HVC parts and it is also an opportunity to produce components with very hard sintered materials.

scholarly journals Do Speed and Proximity Affect Human-Robot Collaboration with an Industrial Robot Arm?

2022 ◽  
Author(s):  
Matthew Story ◽  
Phil Webb ◽  
Sarah R. Fletcher ◽  
Gilbert Tang ◽  
Cyril Jaksic ◽  
...  
Keyword(s):  
Significant Interaction ◽  
Industrial Robot ◽  
Collaborative Work ◽  
Industrial Robots ◽  
Robot Arm ◽  
High Productivity ◽  
The Impact ◽  
Further Development ◽  
Current Guidelines ◽  
Human Robot Collaboration

AbstractCurrent guidelines for Human-Robot Collaboration (HRC) allow a person to be within the working area of an industrial robot arm whilst maintaining their physical safety. However, research into increasing automation and social robotics have shown that attributes in the robot, such as speed and proximity setting, can influence a person’s workload and trust. Despite this, studies into how an industrial robot arm’s attributes affect a person during HRC are limited and require further development. Therefore, a study was proposed to assess the impact of robot’s speed and proximity setting on a person’s workload and trust during an HRC task. Eighty-three participants from Cranfield University and the ASK Centre, BAE Systems Samlesbury, completed a task in collaboration with a UR5 industrial robot arm running at different speeds and proximity settings, workload and trust were measured after each run. Workload was found to be positively related to speed but not significantly related to proximity setting. Significant interaction was not found for trust with speed or proximity setting. This study showed that even when operating within current safety guidelines, an industrial robot can affect a person’s workload. The lack of significant interaction with trust was attributed to the robot’s relatively small size and high success rate, and therefore may have an influence in larger industrial robots. As workload and trust can have a significant impact on a person’s performance and satisfaction, it is key to understand this relationship early in the development and design of collaborative work cells to ensure safe and high productivity.

Cutting Force Model for Heat Assisted Titanium Alloy Milling

2014 ◽  
Vol 887-888 ◽  
pp. 1191-1194 ◽  
Author(s):  
Chang Yi Liu
Keyword(s):  
Titanium Alloy ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Shear Banding ◽  
Cutting Speed ◽  
Constitutive Law ◽  
Force Model ◽  
Machining Processes ◽  
Machine Material ◽  
The Impact

Thermal energy sources have been applied for softening the difficult-to-machine material when it is combined with conventional machining processes. Cutting forces has been reduced during the process. To investigate the plastic deformation property of workpiece materials heated by thermal sources, and its influence to the cutting forces, the analytical model of orthogonal cutting is established. The impact of cutting speed and initial temperature of the shear banding to the cutting forces are taken account of, based on adiabatic shear banding model and Johnson-Cook material constitutive law. The shear banding average shear stress failure criteria has been proposed to decide the fracture between workpiece and chip. Simulation has been carried out and compared with experimental data of laser-heat assisted titanium alloy milling, showing good agreement.

Sign in / Sign up

Export Citation Format

Share Document