Industrial waterjet stripping/cleaning is a prime example of a dull, dirty, dangerous manufacturing process that is ripe for automation, yet it remains a manual task in most instances due to complex workpiece geometry and/or low-volume, high-mix production. Recently developed automated tool trajectory planning algorithms and collaborative path planning frameworks offer a potential solution but are of limited use without corresponding process models and simulation tools to evaluate toolpath quality. Existing process models do not consider the spray impingement angle or the cumulative effect of successive tool passes—both of which are inevitable when spraying geometries that possess concave and/or discontinuous features. This research proposes a novel process model that includes impingement angle and accounts for the cumulative, ablative nature of the process. It also develops a simulation algorithm that applies this model to complex geometries while considering shading effects caused by protrusions and overhangs. Model parameters are determined via a design of experiments approach and nonlinear regression, and verification experiments on complex test parts show good agreement between predicted and measured results. Paired with the aforementioned trajectory planning tools, this research represents a complete robotic process planning solution for waterjet stripping/cleaning of complex parts in high-mix, low-volume manufacturing.
Waterjet Process modeling Process simulation Process automation
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This research was partially supported by National Science Foundation Grant No. 0732686. The authors also gratefully acknowledge the participation of Red River Army Depot in the physical experiments. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the sponsors.
Woods A, Pierson HA (2018) Developing an ergonomic model and automation justification for industrial spraying operations: a case study. In: Proceedings of the 2018 industrial and systems engineering conference, Orlando, FLGoogle Scholar