Article ID: 24-00425
In casting, removing surface defects such as burrs is a crucial finishing process. Burrs, which are unwanted convex defects formed during casting, can adversely affect the product's functionality and aesthetics. This research aims to develop a robotic control system to automate burr deburring from complex-shaped surfaces. The system integrates a compact tool capable of accessing narrow gaps with a 6-degrees-of-freedom robot arm, enabling precise operation in confined spaces. To address the challenge of tool deflection during machining, the proposed system employs feedback control that utilizes both tool-tip reaction forces and position. By regulating the tool feed velocity to maintain a consistent machining reaction force, the system achieves highly accurate and efficient material deburring. Deburring experiments were performed to determine appropriate feedback control parameters. The PI control parameters were determined based on an evaluation of the responsiveness and vibration of the machining reaction force, and the target machining reaction force was determined by evaluating the residual height of the workpiece. The results showed that adjusting the tool feed velocity and compensating for tool deflection using machining reaction force in real-time significantly improved machining accuracy. Furthermore, the target value of the machining reaction force was found to directly influence the quality and speed of the process, with appropriate values ensuring precise and efficient finishing. The system's versatility was validated through experiments on various casting materials, including carbon steel (S50C), aluminum alloy (A7075), and cast iron (FCD4). Analysis of the experimental data revealed a strong correlation between material properties and appropriate control parameters, suggesting that material properties can streamline parameter determination. This adaptability makes the proposed system a promising solution for enhancing productivity and consistency in industrial casting processes.
