In this article, an automatic robotic polishing technique and system is developed for the polishing of titanium alloy curved parts. By means of a designed compliant end-effector with a force sensor, the robotic polishing system with a positionbased explicit force control architecture is first built to perform the polishing operation. Then, a specially designed multi-axis robotic post-processor based on computer-aided design/computer-aided manufacturing is developed to generate the basic position and posture of the polishing tool without any complicated teaching processes. Subsequently, an adaptive Anti-Saturation Integral Separated Fuzzy PI controller, which is able to imitate the manual polishing operation and prevent undesirable vibrations and mechanical collisions, is designed to control the normal contact force. The basic trajectory is changed each time after the current polishing cycle has been finished by online self-learning, and a new basic trajectory is generated for the next polishing cycle. Finally, the effectiveness of the proposed automatic polishing technique is evaluated by actual polishing experiments on titanium alloy (TC11) parts, and the experimental results show that the proposed automatic robotic polishing technique has a perfect control effect on the contact force and thus can achieve a good and uniform surface quality of the part.
During automatic polishing process, path trajectory is an important factor affecting the quality of machining. In this paper, a path generation algorithm based on adaptive Hilbert curves which can cover the curved surface evenly is proposed. The generated path not only makes the coverage density adjustable but also is able to pass through the points on the curved surface in more directions which is helpful to get a finished part without stripes. Using the proposed algorithm, the uniform distributed grid points are obtained in the parameter domain and then these node points with adjustable density can be calculated accordingly. Thus, according to the construction rule of adaptive Hilbert curve, the objective toolpaths are subsequently obtained. After that, by means of a mapping strategy, the path trajectory can be obtained on the physical space. To verify the proposed algorithm, uniform polishing paths with variable density are planned on two typical curved surfaces. The result of the machining experiment shows that the curved mirror-like surface can be achieved, and it also indicates the applicability of the proposed method.
A machining virtual reality system is established by studying the operating procedure of machining. The modeling and optimization method of scene model is put forward. Two different roaming ways, that is the automatic roaming path and the free roaming path, are designed. The process of machine and the operation of virtual worker are simulated based on the technique of modular programming and collision detection in Virtools, enhancing the sense of immersion and reality of the virtual machining process. The system provides a new method for machining experimental instruction.
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