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A novel surface topography prediction method for hybrid robot milling considering the dynamic displacement of end effector

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Abstract

There are extremely high requirements for the surface quality and integrity of parts in the automotive, aerospace, and die/mold industry. Meanwhile, due to the advantages of large workspace, strong flexibility, and low cost, the hybrid robots have shown broad application prospects in the above fields of machining or manufacturing. However, limited by the stiffness of robot joints and links, the surface topography of the milled workpiece is more susceptible to the dynamic response caused by the variation of robot postures and cutting forces. The simulation of the surface topography in the robotic milling process remains a challenging goal. This paper focuses primarily on the dynamic displacement of end effector for the TriMule hybrid robot as well as its impact on the topography of the milled surface. In this paper, a framework model for predicting the topography of milled surface is developed first, and then further perfected by incorporating the dynamic displacement of the robot-tool system in the machining process. In this method, the dynamic model of the robot milling process is developed based on the stiffness of the TriMule hybrid robot within the entire workspace. After that, the finite element method is introduced to discretize the tool and workpiece, and the topography of the milled surface can be regenerated through the Boolean operations and the Z-MAP method. Finally, a series of validation experiments are conducted and the results indicate that the proposed model can be used to predict the topography of the surface milled by the hybrid robot in different postures.

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Funding

This work was supported by the National Natural Science Foundation of China (grant numbers: 52075380 and 52275459).

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Authors and Affiliations

  1. Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Jinnan District, No. 135 Yaguan Rd, Tianjin, 300354, People’s Republic of China

    Xuda Qin, Yifei Li, Gongbo Feng, Zhengwei Bao, Shipeng Li, Haitao Liu & Hao Li

Authors
  1. Xuda Qin
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  2. Yifei Li
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  3. Gongbo Feng
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  4. Zhengwei Bao
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  5. Shipeng Li
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  6. Haitao Liu
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  7. Hao Li
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Contributions

Xuda Qin: investigation, experimental design, data analysis, writing, and editing. Yifei Li: dynamic model of TriMule hybrid robot, finite element model, numerical and experimental data analysis, writing, and editing. Gongbo Feng: investigation, review, and editing. Zhengwei Bao: investigation, preparation of experimental materials, review, and editing. Hao Li: investigation, preparation of experimental materials, review, and editing. Shipeng Li: review and editing. Haitao Liu: review and editing.

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Correspondence to Hao Li.

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Qin, X., Li, Y., Feng, G. et al. A novel surface topography prediction method for hybrid robot milling considering the dynamic displacement of end effector. Int J Adv Manuf Technol 130, 3495–3508 (2024). https://doi.org/10.1007/s00170-023-12814-y

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  • DOI: https://doi.org/10.1007/s00170-023-12814-y

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