PROJECT TITLE :

A Novel Helical Milling End-Effector and Its Application

ABSTRACT:

In the aircraft trade, helical milling is used to get holes in tough-to-machine materials by means that of operating a cutting tool on a helical path into the workpiece. This paper proposes a new helical milling device as an finish-effector of commercial robots. The end-effector employs a right away drive rotary motor with dual-eccentric structure to attain high position accuracy of spindle eccentricity (or radial offset), which indicates the gap between the spindle axis and the outlet axis in the radial direction. So as to eliminate the adverse effects of spindle eccentric rotation, time-varying cutting force, and different unsure disturbances throughout the machining process, a closed-loop servo control system is designed primarily based on the adaptive sturdy management (ARC) methodology. Comparative experiments and machining experiments have been conducted to verify the effectiveness of the proposed helical milling finish-effector. Compared with the PID and deterministic sturdy management controllers, the ARC controller guarantees higher accuracy of the spindle eccentricity in the presence of parametric uncertainties and uncertain disturbances. Average errors and maximum errors of the spindle eccentricity stay below 0.five and one.six μm when machining holes with the eccentricity ranging from zero.5 to four mm, respectively. Surface roughness Ra and roundness of the machined holes in Ti-alloy and carbon fiber reinforced plastic materials are all below three.two and seven μm, respectively. The results show that the proposed helical milling finish-effector is appropriate for hole-machining tasks in aircraft assembly applications.


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