Abstract
Surface polishing is required in many manufacturing sectors. Currently, it demands a large amount of manual work, which is time-consuming, error-prone, and costly. Additionally, it creates hazards for the workers as it may result in many deadly respiratory diseases. Robotic polishing is the solution to these problems. It can improve productivity, eliminate the defects, and provides consistent product quality. In this paper, an effective approach is presented for the robotic polishing of the complex curved surfaces. The key part of the presented method is the tool path planning with controlled force and polishing parameters optimization evaluated using design of experiments (DOE). The tool path planning is aimed at improving the surface quality and the contact area per path. The constraints of joint limits and productivity are also considered. Moreover, its jerk avoidance strategy allows the robot to move swiftly while ensuring a smooth trajectory. The presented method is verified for the polishing of an eyeglass frame. A considerable improvement of 90% on the average roughness is achieved with the maximum acceptable roughness set at 0.02 µm. The polishing operation takes just 79 secs and the average glossiness of 76 G is achieved on the final product along with the successful elimination of scratches on the surface.
Highlights
Polishing is a tedious but important finishing process, which demands a considerable amount of manual work in many manufacturing sectors
Robotic polishing is the solution to these problems, which can improve the working condition of the labor, eliminate the manufacturing defects, and ensure the product quality giving an appealing glossiness to the product
This paper presents a tool path planning approach to polish the complex curved surfaces utilizing a six-axis industrial robot under controlled and optimized force
Summary
Polishing is a tedious but important finishing process, which demands a considerable amount of manual work in many manufacturing sectors. As a serious contender for the robotic polishing, the industrial robot is an automated, programmable, and multipurpose robotic system, which can work in unhealthy and accident-prone environments with high accuracy It has some mechanical constraints, which need to be addressed before using it into the surface polishing of the complex parts. Tool path planning plays a significant role in achieving the good surface quality during the polishing process in the complex structures and requires high reachability, but it offers some relaxation in terms of accuracy [11]. This paper presents a tool path planning approach to polish the complex curved surfaces utilizing a six-axis industrial robot under controlled and optimized force. The rest of the paper is organized as follows: Section 2 presents the proposed method with focuses on force controlling strategy, tool path planning, and method to evaluate the optimized polishing parameters.
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