Automated control of three axis CNC ball end magneto-rheological finishing machine using PLC

Ball end magneto-rheological finishing (BEMRF) is one of the most recent methods developed for nanofinishing of 3D parts. Finishing workpiece of different shapes under varying conditions demands precise control of various parameters. To facilitate accuracy and repeatability of same finishing conditions along with control of motion path over complex geometries, the complete automation of three axis CNC BEMRF machine has been done. The ladder logic diagram for motion and process control is built in RSLogix 5000 while the user interface is developed in Visual C#. Communication between RSLogix 5000 and Visual C# is done using RSLinx open platform communication (OPC) server. The Visual C# code facilitates loading of part program in the user interface screen. It then parses G and M codes and executes them line by line for the desired motion to take place and at the same time it also provides controls for various process parameters. A sample part program was loaded into the interface and successfully tested on an experimental setup to verify and validate its functioning.