An Investigation into the Use of Industrial Robots for Machining Soft and Low Density Materials with HSM Technique

Abstract

The needs to comply with an increasingly competitive international market lead industries to some innovative solutions, such as the use of robotic arms as machine tools. Although these solutions present some well known drawbacks, there are some advantages and niches of application where success is possible. The present work investigates the use of such pieces of equipment to machine aluminum alloys AA2024 applying high speed machining (HSM) technique, assessing surface finishing as a function of different orientation angles between end mill and machined surface. It also tests the best condition to machine foam for prototyping applications. Results indicate that the directions close to the normal are the best compromises because of dynamic stability of the robot arm structure and roughness as low as 4 µm Ra are possible to be achieved in aluminum alloys. A complex shape such as a semi sphere can be easily machined in foam for rapid and accurate prototype machining. Surface finishing can be very smooth and well suitable for industrial applications in such materials.