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Gantry type Lapping Manipulator toward Unmanned Lapping Process for a Large Work Surface

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Abstract

This paper presents a developed manipulator and control method for automatic lapping process applied to a large work surface. A lapping machine consists of a newly designed parallelogram-type 5-axis manipulator and a conventional 3-axis gantry machine. The gantry machine is utilized to precision positioning over a large work area, and the manipulator is controlled by a separate controller for lapping operation in the local surface area which is provided by the CNC controller of gantry machine. The lapping process is, as a first step, needed to remove milling tool marks without injuring original shape, and then to correct the shape error. Wheel compliance becomes different in accordance with the special purpose such as tool mark removal and shape correction. Both processes require high stiffness of the manipulator. In this study, newly designed joints are adopted to secure the stiffness of the joints in both normal and lateral directions. Deadweight of manipulator including wheel motor as well as feed-forward torque control are adopted to suppress the vibration caused by abruptly dynamic cutting force. It was confirmed that the lapping operation was successful in wiping the curved contour without the structural vibration, and that the feed-forward torque control produces twice higher machining efficiency as well as 30% higher surface quality in comparison with the existing compliance control method. The experiment investigated the effects of the abrasive wheel compliance and the dynamic cutting force. In results, the smooth surface was achieved within a satisfied quality level of less than Rz 0.5 μm. It is considered that the proposed manipulator has great potential to be applied in unmanned lapping systems for a large work surface.

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Acknowledgements

This work was supported by the Technology Innovation Program (10053248, Development of Manufacturing System for CFRP) funded by the Ministry of Trade, Industry & Energy (MOTIE, Korea), National Research Foundation of Korea (NRF) granted by the Korea government (MSIT) (Grant No. 2018R1D1A1B07049492), and Institute of Integrated Technology (IIT) Research Project through a grant provided by GIST in 2019.

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  1. School of Mechanical Engineering, Gwangju Institute of Science and Technology (GIST), 123 Cheomdangwagi-ro, Buk-gu, Gwangju, 61005, Republic of Korea

    Sangki Park, Daegwon Koh, Jaeyoon Shim, Jong-Jae Kim & Sun-Kyu Lee

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  1. Sangki Park
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Correspondence to Sun-Kyu Lee.

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Park, S., Koh, D., Shim, J. et al. Gantry type Lapping Manipulator toward Unmanned Lapping Process for a Large Work Surface. Int. J. of Precis. Eng. and Manuf.-Green Tech. 8, 1723–1737 (2021). https://doi.org/10.1007/s40684-020-00274-8

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  • DOI: https://doi.org/10.1007/s40684-020-00274-8

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