Recent progress of chatter prediction, detection and suppression in milling

The poor absolute positioning accuracy of industrial robots is the main obstacle for its further application in precision grinding of complex surfaces, such as blisk, blade, etc Based on the established kinematic error model of a typical industrial robot FANUC M710ic/50, a novel kinematic parameters calibration method is proposed in this paper to improve the absolute positioning accuracy of robot The pre-identification of the kinematic parameter deviations of robot was achieved by using the Levenberg-Marquardt algorithm Subsequently, these identified suboptimal values of parameter deviations were defined as central values of the components of initial individuals to complete accurate identification by using Differential Evolution algorithm The above two steps, which were regarded as the core of this Levenberg-Marquardt and Differential Evolution hybrid algorithm, were used to obtain the preferable values for kinematic parameters of the robot On this basis, the experimental investigations of kinematic parameters calibration were conducted by using a laser tracker and numerical simulation method The results revealed that the robot positioning error decreased from 0994 mm, initial positioning error measured by laser tracker, to 0262 mm after calibration with this proposed hybrid algorithm The absolute positioning accuracy has increased by 4086% than that of the Levenberg-Marquardt algorithm, increased by 4031% than that of the Differential Evolution algorithm, and increased by 2514% than that of the Simulated Annealing algorithm This work shows that the proposed kinematic parameters calibration method has a significant improvement on the absolute positioning accuracy of industrial robot

A novel kinematic parameters calibration method for industrial robot based on Levenberg-Marquardt and Differential Evolution hybrid algorithm

• The challenges faced by milling robots in machining operations are systematically reviewed. • The performance indexes commonly used to evaluate machining systems are highlighted. • The differences between regenerative and modal coupling chatter are compared. • Robotic processing stability is analyzed from two aspects of posture and cutting condition optimization. • Future trends of milling robots and problems to be solved are prospected. Milling refers to a class of material processing methods that relies on a high-speed rotating milling cutter removing extra material to get desired shapes and features. Being distinct from conventional material removal techniques, like CNC machining, robotic milling has the benefits of lower cost, higher flexibility, better adaptability, etc. Therefore, robotic milling has attracted a large amount of researchers’ interest and become an important material-removing way in the machining of complex parts. Trying to present a comprehensive and systematic review on the robotic milling of complex components, this paper elaborates the history and state of the art on stiffness, dynamics, posture planning, chatter, and compensation in the robotic milling process. Furthermore, future potential research topics about robotic milling are also discussed. 

A state-of-the-art review on robotic milling of complex parts with high efficiency and precision

Processing technologies for Nomex honeycomb composites (NHCs): A critical review

Chemical mechanical planarization (CMP) is a wet polishing technique employed to smooth the surface of various materials using a combination of chemical and mechanical forces to achieve finer and longer lines on semiconductor devices. Among the published papers related to CMP, the CMP metal slurry has been the primary focus, and it appears to be the main driver to improve the CMP performance and quality for next-generation devices. Slurry can affect the removal rate, uniformity, defects, and selectivity between the metal and the barrier layer. The material-removal mechanism of metal CMP is determined by the chemical reaction due to chemical solutions compared to the mechanical action, which is due to the abrasiveness of the slurry. We verify that for each user, a chemical knowledge of slurry is required to obtain preferred results. The basic chemical factors of metal CMP slurry are oxidizers, chelating agents, and corrosion inhibitors. This review focuses on the role and effectiveness of each chemical solution by considering the electrochemical characteristics. It will assist in determining the most appropriate solution to further the development of new slurry for next-generation metal CMP.

Slurry components in metal chemical mechanical planarization (CMP) process: A review

The use of industrial robots is widespread in diverse manufacturing fields. Hence, there have been attempts to use robot for machining processes instead of machine tools. However, limited machining accuracy has been a major obstacle hampering the adoption of robotic machining systems. Recently, substantial research has been carried out to address this issue. In this paper, recent progress in robotic machining has been summarized, such as kinematic calibration and compliance error compensation to improve the accuracy of robotic machining. Auxiliary units for improving the performance of robotic machining systems are also discussed.

Robotic Machining: A Review of Recent Progress

Magnetorheological (MR) fluid jet polishing is a material removal process for precision products such as optical elements. It is characterized by a jet flow that is stabilized by a magnetic field, and a highly predictable machining spot. The behavior of the particles in an MR fluid slurry near a target wall surface is conceptually described. In experiments with a BK7 glass specimen, various removal spots are created by impingement of MR fluid jets at velocities of 10~30 m/s, using MR fluids of different compositions, and different processing durations. The tangential MR fluid flow along the part surface is assumed to be responsible for material removal, and theoretical models for the prediction of material removal are developed, using the conventional wear model and granular flow theory. The constitutive relation between the shear stress and the shear rate changes as the jet velocity increases, which has a critical effect on the behavior of material removal. CFD analysis is performed to calculate the wall shear rate. The proposed models agree with the experimental results with respect to the distribution of the material removal rate. Additionally, the surface topographies of polished parts are discussed, with regards to the particle behavior.

Material removal of glass by magnetorheological fluid jet

The mechanism of material removal by electrochemomechanical magnetorheological polishing of glassy carbon (GC) products is studied in this paper. Potentiostatic experiment was performed to examine the electrochemical oxidation mechanism and the associated oxide film growth on GC. A nanoindentation test revealed that the oxide film had lower hardness than did the original GC. An electrochemical impedance spectroscopy experiments were carried out to model the electrochemomechanical material removal mechanism. A series of tribocorrosion tests were conducted to quantitatively study the tribocorrosion synergism.

Mechanism of synergetic material removal by electrochemomechanical magnetorheological polishing

Recently, a new mechanical machining process using electrochemical oxidation was reported. Electrochemical oxidation assisted micromachining was applied to the machining of glassy carbon. The material removal process of the electrochemical oxidation assisted micromachining consists of repeated cycles of oxidation followed by removal of the oxide layer. In this paper, we experimentally investigate and compare the critical chip thickness for ductile mode cutting in mechanical machining and electrochemical oxidation assisted micromachining of glassy carbon. The theoretical critical chip thickness is calculated for mechanical machining of glassy carbon and experimentally verified. The effect of electrochemical oxidation on the critical chip thickness for ductile mode micromachining is also studied for glassy carbon. It is found that the critical chip thickness is increased for the electrochemical oxidation assisted micromachining.

Ductile mode electrochemical oxidation assisted micromachining for glassy carbon

Effect of Electrochemical Conditions on Material Removal Rate in Electrochemical Oxidation Assisted Machining

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