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

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.