Abstract
This paper investigates material removal prediction for contact wheels which are widely used in robotic surface finishing process. In particular, a novel methodology is proposed by using a dynamic pressure sensor as the feedback during the polishing process. Based on the pressure sensor’s feedback, a special form of material removal model is developed taking into account of discretized nature of the dynamic pressure sensor. The curve fitting is subsequently derived to map the discretized material removal prediction into continuous ones. The experimental results are reported to verify the proposed methodology, which has the ability to predict material removal in a precise manner with respect to various polishing forces, workpiece geometries, and contact wheel types.
Similar content being viewed by others
References
Kim J-D, Choi M-S (1997) Study on magnetic polishing of free-form surfaces. Int J Mach Tools Manuf 37:1179–1187
Liao L, Xi F, Liu K (2008) Modeling and control of automated polishing/deburring process using a dual-purpose compliant toolhead. Int J Mach Tools Manuf 48:1454–1463
Su Y-T, Liu S-H, Chen Y-W (2001) A preliminary study on smoothing efficiency of surface irregularities by hydrodynamic polishing process. Wear 249:808–820
Nagarajan B, Chee WJ, Sathyan S (2011) Modeling effects of compliance in coated abrasive tools. Adv Mater Res 325:257–263
Ng WX, Chan HK, Teo WK, Chen I-M (2017) Programming a robot for conformance grinding of complex shapes by capturing the tacit knowledge of a skilled operator. IEEE Trans Autom Sci Eng 14(2):1020-1030
Sun Y, Vu TT, Halil Z et al. (2016) Pressure distribution of serrated contact wheels-experimental and numerical analyses. Int J Adv Manuf Technol. doi:10.1007/s00170-016-9630-0
Sun Y, Vu TT, Yeo SH (2015) Study of pressure distribution in compliant contact wheels for robotic surface finishing. MATEC Web of Conferences 42:03007. doi:10.1051/matecconf/20164203007
Tian F, Lv C, Li Z, Liu G (2016) Modeling and control of robotic automatic polishing for curved surfaces. CIRP J Manuf Sci Technol 14:55–64
Tsai MJ, Huang JF (2006) Efficient automatic polishing process with a new compliant abrasive tool. Int J Adv Manuf Technol 30:817–827
Wang YJ, Huang Y, Chen YX, Yang ZS (2016) Model of an abrasive belt grinding surface removal contour and its application. Int J Adv Manuf Technol 82:2113–2122
Greenwood JA (1997) Analysis of elliptical Hertzian contacts. Tribol Int 30:235–237
Rososhansky M, Xi FJ (2011) Coverage based tool-path planning for automated polishing using contact mechanics theory. J Manuf Syst 3:144–153
Students E, Rudzitis J (1996) Contact of surface asperities in wear. Tribol Int 29:275–279
Zhang L, Tam HY, Yuan C-M, Chen Y-P, Zhou Z-D (2002) An investigation of material removal in polishing with fixed abrasives. Proc Inst Mech Eng B J Eng Manuf 216:103–112
Ju Y, Zheng L (1992) A full numerical solution for the elastic contact of three-dimensional real rough surfaces. Wear 157:151–161
Singh KP, Paul B (1974) Numerical solution of non-Hertzian elastic contact problems. J Appl Mech 41:484–490
Váradi K, Néder Z, Friedrich K (1996) Evaluation of the real contact areas, pressure distributions and contact temperatures during sliding contact between real metal surfaces. Wear 200:55–62
Committee AIH (1990) Properties of wrought aluminum and aluminum alloys, properties and selection: nonferrous alloys and special-purpose materials. Vol 2, ASM Handbook, ASM International, pp 62–122
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Sun, Y., Vu, T.T., Halil, Z. et al. Material removal prediction for contact wheels based on a dynamic pressure sensor. Int J Adv Manuf Technol 93, 945–951 (2017). https://doi.org/10.1007/s00170-017-0473-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-0473-0