Coverage in planar surface polishing by trochoidal tool paths

  • Panagiotis Avrampos
  • George-Christopher Vosniakos
Original Paper
First Online:
Received:
Accepted:
  • 89 Downloads

Abstract

Automation of polishing planar surfaces on 3-axis machining centers is treated from the point of view of defining suitable tool paths that provide full and even coverage of the surface both along and across straight line guide curves, which are routinely produced by any CAM system. A fast but approximate and a slower but precise trochoidal path calculation model are presented. The parameters of the trochoid and the side step are analytically calculated for any given polishing ring diameter in order to safeguard full coverage as well as to avoid over-polishing. Thus, a region of feasible trochoid parameter values is offered to the machinist. Verification of polishing towards full surface coverage is ensured by a simulation tool. Validation of the approach through an actual polishing example is presented.

Keywords

Surface polishing Tool path Trochoid Raster Coverage 
This is a preview of subscription content, log in to check access.

Notes

Acknowledgements

Theodore Mitropoulos is gratefully acknowledged for performing the polishing case study. Mr Manolis Marinakis of Novapax Hellas is gratefully acknowledged for providing technical advice as well as material support for this work.

References

  1. 1.
    Mizugaki, Y., Sakamoto, M., Kamijo, K., Taniguchi, N.: Development of metal-mold polishing robot system with contact pressure control using CAD/CAM data. CIRP Ann. Manuf. Technol. 39, 523–526 (1990). doi: 10.1016/S0007-8506(07)61111-1 CrossRefGoogle Scholar
  2. 2.
    Zhao, J.I., Saito, K., Kondo, T., Narahara, H., Igarashi, S., Sasaki, T., Zhang, L.: A new method of automatic polishing on curved aluminium alloy surfaces at constant pressure. Int. J. Mach. Tools Manuf. 35, 1683–1692 (1995). doi: 10.1016/0890-6955(95)97297-D CrossRefGoogle Scholar
  3. 3.
    Tam, H., Chi-hang Lui, O., Mok, A.C.K.: Robotic polishing of free-form surfaces using scanning paths. J. Mater. Process. Technol. 95, 191–200 (1999). doi: 10.1016/S0924-0136(99)00338-6 CrossRefGoogle Scholar
  4. 4.
    Lee, M.C., Go, S.J., Lee, M.H., Jun, C.S., Kim, D.S., Cha, K.D., Ahn, J.H.: A robust trajectory tracking control of a polishing robot system based on CAM data. Robot. Comput. Integr. Manuf. 17, 177–183 (2001). doi: 10.1016/S0736-5845(00)00052-1 CrossRefGoogle Scholar
  5. 5.
    Hauth, S., Linsen, L.: Cycloids for polishing along double-spiral toolpaths in configuration space. Int. J. Adv. Manuf. Technol. (2012). doi: 10.1007/s00170-011-3608-8 Google Scholar
  6. 6.
    Márquez, J.J., Pérez, J.M., Ríos, J., Vizán, A.: Process modeling for robotic polishing. J. Mater. Process. Technol 159, 69–82 (2005). doi: 10.1016/j.jmatprotec.2004.01.045 CrossRefGoogle Scholar
  7. 7.
    Ryuh, B.-S., Park, S.M., Pennock, G.R.: An automatic tool changer and integrated software for a robotic die polishing station. Mech. Mach. Theory 41, 415–432 (2006). doi: 10.1016/j.mechmachtheory.2005.06.004 CrossRefMATHGoogle Scholar
  8. 8.
    Rauch, M., Duc, E., Hascoet, J.-Y.: Improving trochoidal tool paths generation and implementation using process constraints modelling. Int. J. Mach. Tools Manuf. 49, 375–383 (2009). doi: 10.1016/j.ijmachtools.2008.12.006 CrossRefGoogle Scholar
  9. 9.
    Pessoles, X., Tournier, C.: Automatic polishing process of plastic injection molds on a 5-axis milling center. J. Mater. Process. Technol. 209, 3665–3673 (2009). doi: 10.1016/j.jmatprotec.2008.08.034 CrossRefGoogle Scholar
  10. 10.
    Sun, Y., Feng, D., Guo, D.: An adaptive uniform toolpath generation method for the automatic polishing of complex surfaces with adjustable density. Int. J. Adv. Manuf. Technol. (2015). doi: 10.1007/s00170-015-7140-0 Google Scholar
  11. 11.
    Tsai, M.J., Huang, J.F., Kao, W.L.: Robotic polishing of precision molds with uniform material removal control. Int. J. Mach. Tools Manuf. 49, 885–895 (2009). doi: 10.1016/j.ijmachtools.2009.05.002
  12. 12.
    Tian, F., Li, Z., Lv, C., Liu, G.: Polishing pressure investigations of robot automatic polishing on curved surfaces. Int. J. Adv. Manuf. Technol. (2016). doi: 10.1007/s00170-016-8527-2 Google Scholar
  13. 13.
    Ahn, J., Lee, M., Jeong, H., Kim, S., Cho, K.: Intelligently automated polishing for high quality surface formation of sculptured die. J. Mater. Process. Technol. 130, 339–344 (2002). doi: 10.1016/S0924-0136(02)00821-X CrossRefGoogle Scholar
  14. 14.
    Huissoon, J.P., Ismail, F., Jafari, A., Bedi, S.: Automated polishing of die steel surfaces. Int. J. Adv. Manuf. Technol. 19, 285–290 (2002). doi: 10.1007/s001700200036 CrossRefGoogle Scholar
  15. 15.
    Liu, C.H., Chen, C.-C.A., Huang, J.-S.: The polishing of molds and dies using a compliance tool holder mechanism. J. Mater. Process. Technol. 166, 230–236 (2005). doi: 10.1016/j.jmatprotec.2004.08.021 CrossRefGoogle Scholar
  16. 16.
    Huang, H.Y., Fuh, K.H., Wu, J.S., Tai, Y.H.: A new integrated polishing process design for plastic mold steel to mirror-like surface. Int. J. Adv. Manuf. Technol. (2014). doi: 10.1007/s00170-014-5855-y Google Scholar
  17. 17.
    Farin, G.E.: Curves and surfaces for computer aided geometric design: A Practical Guide. Academic Press Professional, Inc., San Diego, CA, USA (1988)Google Scholar
  18. 18.
    Chaves-Jacob, J., Linares, J.-M., Sprauel, J.-M.: Improving tool wear and surface covering in polishing via toolpath optimization. J. Mater. Process. Technol. 213, 1661–1668 (2013). doi: 10.1016/j.jmatprotec.2013.04.005 CrossRefGoogle Scholar
  19. 19.
    Bagci, E.: Reverse engineering applications for recovery of broken or worn parts and re-manufacturing: three case studies. Adv. Eng. Softw. 40, 407–418 (2009). doi: 10.1016/j.advengsoft.2008.07.003 CrossRefMATHGoogle Scholar

Copyright information

© Springer-Verlag France SAS 2017

Authors and Affiliations

  1. 1.School of Mechanical EngineeringNational Technical University of AthensAthensGreece

Personalised recommendations