A PROCESS MODEL FOR ROBOTIC DISC GRINDING

Automation of deburring and cleaning of castings is desirable for many reasons. The major reasons are dangerous working conditions, difficulties in finding workers for cleaning sections, and improved profitability. A suitable robot cell capable of using different tools, such as cup grinders, disc grinders and rotary files, is the solution. This robot should be completed with sensors in order to keep the quality of the cleaned surface at an acceptable level. Although using sensors simplifies both the programming and quality control there are still other problems that need to be solved. These involved selection of machining data, e.g. feeding rate and grinding force in a force controlled operation based on parameters such as tool type, disc grinder and geometry. In order to decrease the programming time, a process model for disc grinders has been developed. This article investigates this process model and pays attention to problems such as wavy or burned surfaces and the effect of a robot's repetition accuracy in the results obtained. Many aspects treated in this article are quite general, and can be applied in other types of grinding operations.