Research Motivation of
Robotic grinding in manufacturing
As stated
by Ding et al. (1), the multi-axis
tools of CNC Machine as well as the virtue operation majorly grind the complex
components currently. The mainstream approach for the manufacturing of the
parts has been become by the multi-axis CNC grinding because of the harsh
operating environment experienced and the time as well as the labour consuming (2). Although, in the
depth of the application that is limited in arrears to the following reasons
such as the high cost of the exactness machine tools (3), which are most
expensive and has a high millions UA dollars specifically for the large-scale
multi-axis CNC machine tool, the complex configuration without integrated
function of the measurement of the machining as well as the characterized and
the manufacturing mode that is fixed by the parallel machining capability as
well as the unavailable flexible (4).
The new ideas are offered by the
approach which based on industrial robots for the production of the very
complicated components. The robots are looking attractive because of the
competitive price as well as the large extendable workspace by comparing with
the multi-axis tools of the CNC machines that makes them a cost effective
solution to match up the complicated components and especially for those parts
which are comparatively have large dimensions (5). The running
parameters within the real time based on the information of multi sensor
feedback as well as the process knowledge model can be optimized by operations
of the robotic machining, the force sensing as well as the machine vision,
specifically armed with the powerful sensing functions. The break by using the
boundaries of the equipment for the manufacturing traditionally that emphases
on just the axis position of the movement as well the controlling on the speed,
thus leading for the active control of the equipment on the process. Therefore,
it is significant for mentioning that the major barrier for vast usage of the
robots within the exactness of the machining is their repeatability as well as
the low accuracy for the tools of the CNC Machines as well as a very brief
analysis of the tools of the CNC machine as well as those robots which are used
for the industry for the machining (6). However, it has
proposed a large number of the impactful solutions for the reduction of the
positioning the errors as well as the manipulator stiffness within the
industrial machining fields (7). The robotics
grinding is progressively doing replaced the tools of the multi-axis of CNC
machine, as well as the becoming the unconventional part means for the
manufacturing. The results of the research of the robotic grinding of the
complicated components are progressively augmented during the previous one or
two periods, as well as the published journals articles majorly focus on the
feasibility study of the robotic machining and the designing or modelling as
well as the comparison of the dynamics of the machining (8). It mainly conducts
the investigations from the aspects of the robot the grinding path planning,
robot calibration as well as the measurement, the control of the force, the
robot posture or the position optimization as well as the control of the
removal. Furthermore, it is also found, the current ones are majorly expounded
for the perspectives of machining robots as well as the properties of the
machining which is based on the mobile robot machining, the categories of the
operation as well as the robotic chatter machining (9).
Challenges faced by
robotic grinding of Robotic grinding in manufacturing
In
the manufacturing sector, the significant parameters which tend to serve as the
main hurdles to the robotic grinding are as given:
Acquiescence concerns:
Other than the precision and accuracy related challenges, which take place at
the system level, the components of the robotic grinding systems are also of
immense importance. These components are a part of the geometrical accuracy of
the system. It is mandatory to consider the compliance control due to its
impact on the contact state along with the pressure influence for the purpose
of having the control over machining allowance (5). The consistent
power control procedures can be condensed into four classes: impedance control,
cross breed power/position control, versatile control as well as canny control.
There is huge advancement to the practices of robotic systems for the grinding
purposes. Still, the force control is less in practical engineering applications.
This
is predominantly attributable to the troubles in precise demonstration of
mechanical elements and usage of power control calculations, which are
essentially obliged by the transparency of business modern robots. In the
interim, the current power/position control in mechanical crushing expects to
lessen the surface harshness of parts and gives less consideration to the
exactness of shape and position. Indeed, for some perplexing segments, for
example, turbine sharp edges, they have unpleasantness necessities, yet
additionally providing with the prerequisites for forming the exactness.
For
robotic grinding systems in the manufacturing industry, the major challenge
regarding the high-precision force/position control is recorded. It is about uncovering
the power/position coupling in two symmetrical subspaces. The aim behind it is
to provide the guarantee for the power controlled ordinary bearing in case of
contact-force. Also the big question is to deal with guarantee for providing
the direction which is to follow precision in force-controlled unrelated
course?
Precision concerns:
For the current research work, the precision concerns of the robotic grinding
systems in the manufacturing industry are considered to be the biggest
challenge. For the robotic grinding systems the efficiency as well as the
accuracy is desirable. This phenomenon is all about measuring the area related
to the performance of the work. After doing this, the pin-points need to be
identified as per already available theoretical models. By doing this, the
details related to the corresponding position are better & extracted
quickly (7).
The
main purpose for this evaluation is the cross-check for both the designed
models as well as the measured points. It is done with the help of performing
the calculations for the parameters related to the rigid transformation. The
major challenges that prevail to the way of performing such calculations may
include as given: the accuracy as well as the precision cannot be determined
regarding the absolute positioning. The complicated components cannot be
scanned properly based on the existing robotic systems for the manufacturing
industry. The significant elements for
affecting the favourable rigid transformation may include the local data
missing, Gaussion noise, as well as the uneven point compactness. It tends to provide
the failure to the traditional algorithm for matching purposes.
The
components over the surface tend to provide with the incorrect values for the
robotic grinding in manufacturing. It may include the profile errors as well as
the allowance distribution problems. It can be said the designed models as well
as the measured points need to be cross-checked with the intense accuracy &
the precision. It is basically perceived to be the key parameter for making the
robotic grinding systems to perform accurately along with their position points.
Accommodating concerns:
In case the unpredictability of the machining task enhances, it tends to offers
the constraints for the machining capacity of a grinding robot for the
manufacturing sector. The transactional relevancy helps the robotic grinding
structures in the manufacturing industry to work as a whole i.e., by making use
of different components. For the said purpose, the components are perceived to
be the varying operators which are to assist the proper functionality of the
grinding robots. It better helps to indicate the points of interest in
effectiveness, adaptability and adaptability, particularly for huge scale
complex structures (2).
It
can be said that for the manufacturing industry, the major components of the grinding
robotics are discernment, multi-sensor information combination, multi-robot
design, and resolution of the conflict. For the case of multi-robot agreeable
control, the conventional strategies partition the entire framework into
various slave-master frameworks and perform remote facilitated control on every
subsystem. By doing this it is tried to bring the improvements to the
dependability and synchronization of numerous frameworks through the
cooperative control of Internet model.
It
is hard to acquire the worldwide data of the work piece, be that as it may be,
for the synchronous machining of huge scale complex structures. Also, the
requirement connection between different robots is mind boggling and hard to
tackle precisely. It tends to introduce the interest on the constant detecting
and data move of numerous robots. What's more, it is better suggested to
advance robot movement control techniques. These are appropriate for shared
machining, and build up the controller just as community oriented control
programming to acknowledge task designation and obstruction evasion (10).
Below is given the flow chart for
model processing for grinding robots in the manufacturing industry.
Figure
1: Flow-chart for model processing for grinding robots in the manufacturing
industry
Typical applications of
robotic grinding for the complex components
A. Use of turbine blades
for Robotic belt grinding in manufacturing
a. Background along with
the existing problems
Currently,
the ideals of manual grinding as well as multi-pivot CNC belt pounding help to
process the cutting edges which is related to the most part wrapped up by
Contrasted and the sharp edge profile. If we talk about the thickness of the
main and trailing edges of the cutting edge then we find it is the thinner one
as given: (to be R0.1mm level). Both the bending as well as the machining way
change enormously. It represents a test to the exactness granulating of sharp
edges. While for the multi-pivot CNC grinding, the cutting edge clipping
situating mistake is equal to the disfigurement blunder of the sharp edge. It
is related to the request for size of the said system. So, it is required that
CNC grinding must be founded on the exact estimation of the edge clasping state
(11).
Be
that as it may, the machining method of the current multi-hub CNC pounding
hardware is fixed (for example uninvolved granulating, no adaptability and
parallel preparing capacity). Combined with the perplexing arrangement, it is
hard to shape the mix of "measurement-machining". The creators'
exploration group collaborated with Wuxi Turbine Blade (WTB) Limited Company to
research the automated belt crushing of different sorts of steam turbine sharp
edges and flight edges, and made extraordinary enhancements in both machining
effectiveness and surface quality.
For
instance, the hour of mechanical belt granulating one meter long steam turbine
cutting edge was abbreviated to a little ways from the 45 minutes by manual
pounding activity, the precision of the edge profile was expanded from ±0.15mm
to ±0.1mm, and the surface harshness was improved to Ra0.4 from Ra0.8
correspondingly. In any case, it was found from the long haul nearby tests that
mechanical belt granulating of complex sharp edges is essentially looked with
the accompanying issues:
·
Unevenly disseminated
pounding expulsion remittance. Most importantly, the cutting edge expulsion stipend
isn't equally dispersed before pounding, and this is basically identified with
the past procedure. For instance, in the wake of manufacturing the air motor
blower sharp edges, just the cutting edge roots, canals and driving and
trailing edges should be ground and cleaned, and the machining remittance
dispersion at the main and trailing edges is very uneven from 0.042 to 0.224
mm. Besides, the sharp edge bracing blunder additionally influences the
machining remittance circulation of the edge driving and trailing edges. Due to
the unevenly conveyed machining stipend and the thin machining data
transmission, the "unfilled running marvel" may happen in the edge
area of the cutting edge, and the uneven pounding power irritates the babble,
in this manner bringing about the granulating marks which is likewise
significant to the firmness of robot-clip sharp edge framework (8).
·
Difficulty in controlling
the crushing contact power. From one viewpoint, the guideline of consistent
weight crushing is normally used in rough belt pounding, yet this strategy is
clearly hard to adjust to the edge evacuation of uneven machining edges. In the
interim, the pounding procedure joined by the wear and strip off of abrasives,
makes the thickness of the rough belt change. Step by step instructions to
guarantee the exact evacuation of the cutting edge from the procedure puts
appeal on the contact power control. Then again, since the main and trailing
edges of the sharp edge are thin, the crushing is inclined to torsional and
bowing distortion (9).
To
guarantee the exactness of the cutting edge profile, a little contact power
underneath 10 N is carefully required. Be that as it may, on account of
adaptable contact with clear flexible shape, how to keep exorbitant
disfigurement blunder from the granulating hardware additionally puts a
pressing requirement for contact power control.
Strategies for successful
robotic grinding
Some
strategies for the successful robotic grinding of the complicated components
are discussed here, which are explained in the further paragraphs. It can
conduct the following effective strategies as well as the potential solutions
for the construction of the combined measurement, manipulating the machining
function to overcome the challenges confronted by the complicated components of
the robotic grinding for the robotic grinding system.
1). Process Parameter
optimization of Robotic grinding in manufacturing
The
process parameter optimization is used for the improvement of the integrity
surface of the workpiece robotically machined. Cycle-time and belt oscillation
frequency the researchers did analyze the effects of two significant process
variables in belt finishing, on the forming surface as well as specificities
finish of steel that is hard by an approach of energetic tribo. A systematical
investigation on floor integrity of nickel-based first-rate alloy in robotic
belt grinding used to be carried out from the aspects of morphological
structure, floor roughness, residual stresses, and structural area size. The
consequences of abrasive grain size, contact force, linear belt speed and feed
fee on the surface roughness in abrasive belt grinding of aviation blades, and
the most efficient manner parameters were decided by means of examining the
response surface. The outcomes indicate that the continuous partial dynamic
recrystallization coupled with mixed outcomes of plastic deformation and
thermal therapy contributes to the excessive qualitative floor integrity, and
each grinding pressure and belt pace are discovered to appreciably influence
the floor integrity.
The
machining as well as the flexibility contact along with the wide strip that are
two prominent compensations or the pros for the system of the robotic belt
grinding as well as it may be widely used for the improvement of the quality of
the surface as well as the effectiveness of the robot but the pieces of the
work with the statue of the curvature (12). The running
parameters within the real-time based on the information of multi-sensor
feedback, as well as the process knowledge model, can be optimized by operations of the robotic
machining, the force sensing as well as the machine vision, specifically armed
with the powerful sensing functions (13). Therefore, it is
significant for mentioning that the major barrier for vast usage of the robots
within the exactness of the machining is their repeatability as well as the low
accuracy for the tools of the CNC Machines as well as a very brief analysis of
the tools of the CNC machine as well as those robots which are used for the
industry for the machining.
The
research on the grinding planning path for the robotic machines may be found by
the study of the kinematics of the contact. The universal demands of the
technologies of the grinding of the belt must be satisfied by the processes of
the grinding, as well as the most significant thing is to form the contact
wheel imitate the features of the geometrical on the contact local area (14). The results of the
research of the robotic grinding of the complicated components are
progressively augmented during the previous one or two periods, as well as the
published journals articles majorly focus on the feasibility study of the
robotic machining and the designing or modelling as well as the comparison of
the dynamics of the machining (15).
The
length of the curve among the cutting locations of the neighboring develops the
longer for ensuring the efficiency of the processing. Furthermore, to make sure
or investigate the accuracy of machining (13), the curve length
becomes shorter for the local areas along with the larger curvature. For the
intersection along with the target surface of the section for grinding, a
series of planes are also developed as well as the corresponding curves of the
social corresponding are obtained. The length of the curve among the cutting
points of neighboring for every curve is optimized by the addition of the
cutter location at the local area along with those curvatures which are looking
big the size. The paths of the grinding generation method consist of the length
spacing optimization is shaped (14). The validity of the
design, structure as well as the process is completely approved by the offline
simulation as well as the surface quality during the experiments of the
grinding with the process is enhanced. The theoretical support for the
smoothness, as well as the path of the robotic grinding of the surface’s
accuracy is provided by the method of the planning of the path. (14).
2). Machining error Compensation of
Robotic grinding in manufacturing
As
the authors, Chen & Dong (3) described that the
robotic machining was reported in early studies within the 1990s. Eventually,
the potential of robot applications in the machining has realized that there
are a lot of researches on the machining of robots available in the shape of series
worldwide. The researchers Chen & Dong (3) in this paper will
take a look at the modern development of the machining of robot. Such
development works may be roughly classified within the proposed researches on
the system development of the robot machining, the compensation, stiffness of
the modeling or dynamic, path planning of robot machining, as well as the
chatter analysis or vibration analysis together with the path tracking (16). Such kind of researches
on the robot machining will clearly improve the efficiency as well as the
accuracy of robot and for development of such kind of robot machining systems,
provision of the useful references for the tasks one time thought to be capable
by CNC machines (17).
As
described by the authors Chen & Dong (3), for the advancement
of the technology of the robotic machines to the competitiveness of the systems
as well as the next level, which is more complicated and practical could be
developed. So that’s why the researchers (3) propose that the
next studies on the machining of robots must have to focus on the comparison of
the robotic machines, the difficulty in planning of the path based on the map,
the optimization of the robotic link of arm, scheduling as well as the planning
for a line of machining robots.
Since
the stiffness of the robotic grinding setup was at least one order of magnitude
lower than established grinding machines, the complete gadget stiffness such as
a tool, workpiece, and robot stiffness in robotic grinding operation is
regarded to be a determination that motives the deviation of machining
accuracy. Focus on the huge impact of tool deflection on the machined surface
in robotic grinding, the work derived a novel grinding force model and
real-time tool deflection 21 compensation algorithm to effectively classify the
grinding operation regimes and predict the grinding forces (15).
Critical issues and
Methodologies
As
Zhang et
al. (12) stated as this
research is providing brief information about critical issues as well as some
methodologies for the improvement in the machining performance of robotics
along with those robots that are flexible in the industry. The stiffness of the
robots is importantly lower as compared with the CNC machine while in the
outcomes it has low productivity as well as unacceptable quality. Furthermore,
the problem is treated with the methodology of the novel, which includes the
real-time deformation compensation for the quality, the stiffness of modeling
as well as the controlled material removal rate (12) to make the system
efficient. The experimental outcome shows that better surface accuracy, as well
as higher productivity, may be attained, indicating a promising as well as the
use of the practice of industrial robots to applications, which is not possible
at the current time (4).
Zhang et al. (12) described that
to minimize the machining blunders generated via the no uniform material
removal in belt grinding, proposed a second-order osculation primarily based
method for grinding marine propeller blades, and the outcomes confirmed that
the machining error could be controlled below the given tolerance. Particularly
in belt grinding of blades, the abrasive belts with distinct materials under
the motion of bendy contact wheel would undergo giant elastic deformation, and
this will reason deformation error of the blade area processing (16), and finally have an
effect on the blade profile accuracy and the surface quality. Actually, the
effect of elastic deformation at tool-workpiece interface in abrasive belt
grinding is extra sizeable and was once appreciably investigated by using
setting up an average contact pressure mannequin to evaluate the friction
coefficient and abrasive wear rate (12).
Wu
et al. (18) stated that the
model of the systematic geometry had been presented to the standardization of a
modern designed the blade of 5-axis turbine robotic machine for grinding. To
get higher level efficiency as well as the great accuracy for grinding of the
turbine blades, through the removal of the process of hand grinding, this
machine is designed (18). Furthermore, the
design of the machine is totally different from the tools of the competitive
machine, the topology for that is RPPPR in which R is rotary while P is
prismatic. To identify by investigating, maintaining, managing as well as
improving the accuracy of the calibration, recommended for the acceptance
testing as well as the performance assessment, an error quantification is the only
way.
The
error modeling technique in the symmetric geometry is applied as well as the
dependant position, as well as the position of the independent errors, is
recognized but the machine consideration machine as the stiff structure of the
robots by removing the errors of setup of the cutting tool as well as the piece
of work. Moreover, thirty-nine of them are identified for having the effective
errors, as well as these, are suggested to get the total effect among the piece
of work as well as the cutting tool within the volume of the workspace. It uses
the homogenous transformation matrices as well as the techniques of the rigid
body kinematics (18).
Material removal rate
Modelling of Robotic grinding in manufacturing
As
stated by Bernd & Xiang (12), the key indicators
for uring the profile with the accuracy as well as the accuracy in the
dimensions of surfaces of the machine within the robotic grinding are the
material removal rate. The premise for the high performance of robotic
grinding, such as the conventional operation for wheel grinding is to clarify
the mechanism of the removal of the material meanwhile it is largely influenced
by the properties of the material, the information of the geometry as well as
the parameters process.
As
described by Bernd & Xiang (12),
since the cloth removal is not definitely a geometric computation in robotic
belt grinding, later work more focuses on its theoretic modeling, which is seen
as a contact problem between an elastic body and a rigid body. The researchers
considered the fabric removals as the pressure distribution in the contact area
and put ahead an SVR-based nonlinear force calculation model primarily based on
the regular global grinding model. Then the real-time simulation of the
robot-controlled belt grinding strategies will become possible (12).
Particularly
for the abrasive belt grinding, the pioneered work 14 experimentally
investigated the outcomes of contact pressure between tool and workpiece, belt
pace and feed fee on the fabric removal fee in the course of robotic belt
grinding of turbine-vane overhaul, and found that the normalized fabric
elimination amount used to be elevated with the make bigger of the contact load
and belt speed, and with the limit of the feed rate (12).
High-Quality Belt
Grinding System of Robotic grinding in manufacturing
As
stated by Shuihua & et al. (13), robotic belt
grinding is very useful technique to make the pieces of work along with the
complex free-form geometries. Therefore, the control strategies as well as more
sophisticated modeling because of the minimum stiffness in the system are
called for. A novel model for the approximation of material removal is
presented in this literature within the grinding process of robotic belt. Two
process parameters, such as the contact force as well as the velocity of the
robot among the contact wheel and the piece of work are analyzed within the
process model. Furthermore, for the estimation of the distribution of the
pressure, (13) a superposition
technique is also introduced in the contact area. The existing method highly
decreases the time for the computation as compared to Finite Element Analysis
(FEA) method as well as also gives the equation explicitly to analyze the
real-time system.
Moreover,
on material removal, a shape-dependent model is also developed for the
estimation of the removal of material or material removal. To donate the
ability of the material removal system in particular areas, the model presents
the local coefficients. Simply, the proposed methodology may adapt necessarily
for the prices of work along with the complex geometry, while the experimental
outcomes confirmed the accuracy as well as the effectiveness of the model (13).
4). Contact Force Control of
Robotic grinding in manufacturing
Figure
2: Association between components of the grinding robots in the manufacturing
industry
An
inexorably significant utilization of modern grinding robots is in the zone of
manufacturing, for example, crushing as well as the manufacturing processes.
For the said processes the contact force control of the robots is related with
the procedure of the metal expulsion. It is perceived to be a significant
thought. As per the available literature, there exist the variations regarding
the contact force control strategies with the perspective of the grinding
through robotics in the manufacturing industry. It can be either in the form of
contact force control through the adjustments of the robots having simple as
well as the open loop positioning or “through the arm” robotic control. The
former will provide with the passive-end effector and the later will provide
with the active end effector. It is due to the technological advancements to
the robotic systems. In the said domain, a lot of work has been performed in
order to introduce the advanced methods for the robotic force controllers.
For
current type of contact force controls, the firmness, latency, as well as
mechanical framework’s damping can better be transformed. It helps to manage
the robot's reaction for various info collaboration powers with respect to the
manufacturing processes in the manufacturing industry. In most of these
examinations, in any case, controls for the dynamic power are better executed.
It does not include any type of criticism regarding the metal evacuation procedures.
The use of the plate granulating is not only popular for the manufacturing
field but also for the car foundries, car businesses as well as the delivery
yards etc. The main reason behind using this process is the assistance for the
evacuation of deformities, scales along with the welding dots from the
manufacturing machinery (1).
For
the purpose of adjusting the position of the robot, which is designed for
providing with the robotic grinding in the manufacturing, a power controller
better helps to serve this objective. The main motive for making use of the
power controllers include as given:
·
The rate for the metal
evacuation is predetermined. By making use of the contact force control, the
rate for the metal evacuation can be maintained.
·
The geometric blunders,
which take place due to the contact force control, are reduced to the maximum
extent.
·
In case of the cutting
processes, this control provides with the guarantee regarding the forestall
work-piece bum.
In
the manufacturing industry, the use of the robotic grinding is suggested. The
contact force controllers are helpful for managing the granulating power within
the sight of a stage aggravation in the organizational stature.
Notwithstanding, the reason given for the said purpose includes as given: the
presentation of the contact force control, in the working area, is
exceptionally delicate for the robotic arm area. Versatile control was seen as
important to make up for the varieties for the parameters of the framework. The
purported "long-extend prescient controllers" are fit for the elite systems
as well as the applications. For example, the control of adaptable automated
frameworks can be considered in this regard. Specifically, it is an extremely
appealing control procedure for machining applications. For example, in the crushing
it is necessary that power direction can be resolved during the undertaken arrangements.
It
is also mandatory to carry out the procedures with the consideration of the
assurance of the quality. This is better done by following up the processing
cycle as given below: It can be seen that the cycle takes into consideration
both the process adoption as well as the quality assurance. The process
adoption is all about the automation of the process adaption along with the
generation of the partial programs for the processing of the materials and the
substances.
The
high-quality of the processes and the outcomes is better ensured by selecting
the technical parameters of the robots for the grinding purposes in the
manufacturing industry. It is not enough to carry out the procedures rather the
quality assurance is also as significant as the process itself. It is done by
identification of the defects through well-defined evaluation processes. It can
be done by adopting both either the manual classification of the defects or the
automated identification of the same (6).
References of
Robotic grinding in manufacturing
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