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Experimental investigation and modeling of material removal characteristics in robotic belt grinding considering the effects of cut-in and cut-off

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Abstract

Motivated by our previous work which proposed an improved microforce model considering the effects of cut-in and cut-off in robotic belt grinding operation, we further extend this novel idea into the analysis and optimization of the cut-in and cut-off phenomenon which seriously affects the surface contour accuracy and machining quality. Firstly, a practical material removal rate (MRR) model is introduced to characterize the material removal characteristics, especially at the cut-in and cut-off paths. Then, a strategy framework using the combination of active and passive force control, variable-feed finishing, and longitudinal grinding style is constructed to further enhance the surface profile accuracy and processing quality. Finally, robotic machining experiments of titanium alloy test workpiece are implemented to test the reliability and reasonability of the strategy framework.

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Abbreviations

LVDT:

Linear variable differential transformer

MRR:

Material removal rate

a p :

Experimental grinding depth of cut [mm]

b :

Effective contact width between contact wheel and workpiece [mm]

E 1 :

Modulus of elasticity of the contact wheel [GPa]

E 2 :

Modulus of elasticity of the test workpiece [GPa]

F a :

Axial grinding force [N]

F n :

Normal grinding force [N]

F t :

Tangential grinding force [N]

F s :

Preset normal force [N]

F e :

Difference value of preset force and real feedback force [N]

h :

Theoretical robotic grinding depth [mm]

h d1 :

Material removal depth at the cut-in path [mm]

h d2 :

Material removal depth at the cut-off path [mm]

h w1 :

Material removal width at the cut-in path [mm]

h w2 :

Material removal width at the cut-off path [mm]

k1:

Absolute value of the slopes at the cut-in path

k2:

Absolute value of the slopes at the cut-off path

L :

Width of test workpiece [mm]

L t :

Length of test workpiece [mm]

m 1 :

Proportion of V1 to the total volume loss V

m 2 :

Proportion of V2 to the total volume loss V

m 3 :

Proportion of V3 to the total volume loss V

n 1 :

Proportion of Qw1 to the total material removal rate Qw

n 2 :

Proportion of Qw2 to the total material removal rate Qw

n 3 :

Proportion of Qw3 to the total material removal rate Qw

P :

Load force which equals to the normal grinding force Fn [N]

p :

Function of the three major parameters: Fn, vc and vr

p 0 :

Optimal grinding parameters

P s :

Input cylinder pressure [MPa]

P e :

the pressure convert to voltage U [MPa]

P f :

Feedback pressure [MPa]

Q w :

Total material removal rate [mm3/s]

Q w1 :

Material removal rate on the cut-in path [mm3/s]

Q w2 :

Material removal rate on the normal path [mm3/s]

Q w3 :

Material removal rate on the cut-off path [mm3/s]

Q 0 w :

Total material removal rate based on traditional calculation method [mm3/s]

R o :

Radius of contact wheel [mm]

t 1 :

Contact time on the cut-in path [s]

t 2 :

Contact time on the normal path [s]

t 3 :

Contact time on the cut-off path [s]

v c :

Contact wheel speed [m/s]

v r :

Robot feed velocity [mm/s]

V 1 :

Material removal volume loss on the cut-in path [mm3]

V 2 :

Material removal volume loss on the normal path [mm3]

V 3 :

Material removal volume loss on the cut-off path [mm3]

μ :

Force ratio

δ :

Pressed depth [mm]

v 1 :

Poisson’s ratio of the contact wheel

v 2 :

Poisson’s ratio of the test workpiece

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Correspondence to Dahu Zhu or Sijie Yan.

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Xu, X., Chu, Y., Zhu, D. et al. Experimental investigation and modeling of material removal characteristics in robotic belt grinding considering the effects of cut-in and cut-off. Int J Adv Manuf Technol 106, 1161–1177 (2020). https://doi.org/10.1007/s00170-019-04660-8

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Keywords

  • Material removal rate
  • Cut-in and cut-off phenomenon
  • Surface profile
  • Optimization strategy