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Abstract
Chattering is one of the most important factors affecting productivity of robot machining. This paper investigates the pose-dependent cutting stability of a 5-DOF hybrid robot. By merging the complete robot structural dynamics with the cutting force at TCP, an effective approach for stability analysis of the robot milling process is proposed using the full-discretization technique. The proposed method enables the computational efficiency to be significantly improved because the system transition matrix can be simply generated using a sparse matrix multiplication. Both simulation and experimental results on a full size prototype machine show that the stability lobes are highly pose-dependent and primarily dominated by the lower-order structural modes.
Highlights
Thanks to many advantages such as lower cost, acceptable accuracy, flexibility and reconfigurability, industrial robots have become popular for the in-situ large parts manufacturing, light machining, milling and drilling for example [1]
The results show that the regenerative chatter is primarily dominated by the local tool-spindle modes at high milling speed, while the mode coupling chatter is mainly dominated by the lower-order structural modes at low milling speed
Based on the semi-discretization method (SDM), Cordes et al [7] predicted stable boundaries affected by lower-order structural modes of the robot milling in low radial immersion condition with high accuracy
Summary
Thanks to many advantages such as lower cost, acceptable accuracy, flexibility and reconfigurability, industrial robots have become popular for the in-situ large parts manufacturing, light machining, milling and drilling for example [1]. Different from conventional machine tools, the lower-order dynamics of a robotic system is highly pose-dependent [8, 9]. This feature requires the cutting stability over entire workspace to be predicted efficiently and accurately. Various algorithms for stability prediction have been developed [10-20], and the most representative ones are the semi-discretization method (SDM) [15-17] and full-discretization method (FDM) [18-20] The former formulates the response function of the robot milling dynamics as the delayed differential equations (DDEs) using direct integration scheme. Based on the SDM, Cordes et al [7] predicted stable boundaries affected by lower-order structural modes of the robot milling in low radial immersion condition with high accuracy.
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