Abstract
Robotic machining is an alternative to manufacturing processes that combines the technologies of a high-performance machine tool with the flexibility of a 6-axis jointed arm robot. With their large working area, industrial robots are of particular interest for processing large-volume components and large structures, like aircraft components. An influencing variable, which is particularly relevant for milling processes with industrial robots are the cutting force F and the resulting dimensional deviation D. Milling tests of titanium alloys were carried out with an industrial robot and the results compared with a conventional machine tool. Due to the low thermal conductivity and high chemical reactivity of the Ti-6Al-4V alloy, heat is generated and increases the temperature in the contact region of the cutting tool/work piece. That has an impact on the cutting tool wear and increases the cutting force F, and consequently, the dimensional deviation D and the machined surface quality. The aim of the investigations is to find a suitable parameter selection and machining strategy for machining titanium alloys with minimal deviation D and an appropriate surface finish.
Highlights
In the last decade, robotic processing has evolved from a basic research topic to a production technology for industrial use (Uhlmann, Wacinski, and Dethlefs 2012)
For machining titanium alloy with a CNC machine tool, the best roughness with Ra = 0.40 μm and Rz = 2.45 μm was achieved with cutting depth ap = 1.25 mm
These results are mainly correlated to robot instability during trochoidal milling to depth of cut ap = 1.00 mm
Summary
Robotic processing has evolved from a basic research topic to a production technology for industrial use (Uhlmann, Wacinski, and Dethlefs 2012). Robotic machining is an innovative production technology that combines the advantages of a highly accurate machine tool with the flexibility of a 6-axis jointed arm robot. Due to their relatively low investment costs K compared to machine tools, milling robot systems represent a cost-effective alternative. Continuous improvement of the industrial robots regarding stiffness c and path accuracy AT results permanently in new industrial applications (Abele et al 2013). Another advantage of inexpensive industrial robots is the relatively large usable workspace. The use of industrial robots is changing from assembly, logistics and handling tasks to applications in machining operations
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