Analysis of Contact Conditions Based on Process Parameters in Robotic Abrasive Belt Grinding Using Dynamic Pressure Sensor

Abstract

The material removal in complicated geometries is the principal objective for machining with compliant abrasive tools in aerospace industries. Realizing ideal material removal rates with fine tolerance in tertiary finishing process such as abrasive belt grinding is essential. This makes it fundamental to look in more detail at the process parameters/variables that affect the material removal rate. However, the relationship between the material removal rate and process parameters is not well understood. Previously, five parameters such as belt speed, feed, rubber hardness, grit size and force applied were studied in correspondence with the depth of cut, and it was found grit size plays a dominant role in the grinding process [1]. In this study, the influence of four parameters out the five parameters namely belt speed, feed, rubber hardness and force are investigated using a dynamic pressure sensor. Three level of input for each parameter was considered. Experimental trials were conducted by varying the levels of one parameter and maintaining a constant level for other three parameters. Based on the experimental trials performed using the dynamic pressure sensor, a correlation between the three levels considered for each parameter is identified based on the contact conditions. It was observed that pressure distribution based on the contact condition using the pressure sensor for the parameter considered followed the same results as predicted by ANOVA [1]. This research work describes a systematic approach to analyse process parameters based on contact conditions using a pressure sensor to understand material removal in a compliant abrasive belt grinding process.