A New Method for High-precision In-situ Milling Edge Processing of Industrial Robots for Large Composite Thin-walled Components

doi:10.3901/JME.2025.07.120

Abstract

Abstract: Addressing the challenges of weak rigidity and difficulty in ensuring cutting accuracy of large composite thin-walled components, as well as long design and manufacturing cycles and high processing costs of profiling tooling, a new method for high-precision in-situ milling edge processing of large composite thin-walled components using reconfigurable flexible tooling is proposed. This studg designs a robotic milling system for large composite components. Firstly, for the trajectory tracking problem of large composite components’ spatial curves, a vision-guided robot trajectory accuracy compensation algorithm is studied in combination with a binocular vision measurement system, and a high-precision servo control law is designed to achieve high-precision trajectory tracking control of the robot. Then an dynamics modeling method for large thin-walled components and flexible tooling is studied, and an optimal support layout strategy for flexible tooling based on intelligent optimization algorithm is proposed to improve the support rigidity of large complex thin-walled components. Further, an ultrasonic machining tool is designed and ultrasonic vibration milling processing technology is studied. Finally, through test verification, the processing vibration and trajectory errors of industrial robots are effectively reduced, and high-precision machining of large composite thin-walled components by robots is achieved.

Key words: industrial robot, large composite, milling edge, visual guidance, dynamics modeling, ultrasonic vibration cutting

CLC Number:

TP241

TIAN Wei, LI Pengcheng, MIAO Yunfei, LIAO Wenhe, DONG Song, MENG Dan. A New Method for High-precision In-situ Milling Edge Processing of Industrial Robots for Large Composite Thin-walled Components[J]. Journal of Mechanical Engineering, 2025, 61(7): 120-133.

Add to citation manager EndNote|Reference Manager|ProCite|BibTeX|RefWorks

URL: http://www.cjmenet.com.cn/EN/10.3901/JME.2025.07.120

http://www.cjmenet.com.cn/EN/Y2025/V61/I7/120

References

[1] 王亮，李东升. 飞机数字化装配柔性工装技术体系研究[J]. 航空制造技术，2012(7)：34-39. WANG Liang，LI Dongsheng. Flexible tooling technology system for aircraft digital assembly[J]. Aeronautical Manufacturing Technology，2012(7)：34-39.
[2] SCHWAKE K，WULFSBERG J. Robot-based system for handling of aircraft shell parts[J]. Procedia CIRP，2014，23：104-109.
[3] SHUANG M，LIANYU Z，WEI F，et al. Intelligent layout optimization of reconfigurable flexible fixture for assembling multiple aircraft panels[J]. The International Journal of Advanced Manufacturing Technology，2023，126(3-4)：1261-1278.
[4] GUO F，WANG Z，KANG Y，et al. Positioning method and assembly precision for aircraft wing skin[J]. Proceedings of the Institution of Mechanical Engineers，2018，232(2)：317-327.
[5] HU F，LI D. Process planning and simulation strategies for perimeter milling of thin-walled flexible parts held by reconfigurable fixturing system[C]// Third International Conference on Measuring Technology and Mechatronics Automation. IEEE，2011，2：922-926.
[6] 郭飞燕，王仲奇，康永刚，等. 飞机柔性装配工装设计[J]. 航空制造技术，2014(16)：12-16. GUO Feiyan，WANG Zhongqi，KANG Yonggang，et al. Design of the flexible assembly tooling for aircraft[J]. Aeronautical Manufacturing Technology，2014(16)：12-16.
[7] GHARAATY S，SHU T，XIE W F，et al. Accuracy enhancement of industrial robots by on-line pose correction[C]// Proceedings of the Asia-pacific Conference on Intelligent Robot Systems，2017：214-220.
[8] 曲巍崴，董辉跃，柯映林. 机器人辅助飞机装配制孔中位姿精度补偿技术[J]. 航空学报，2011，32(10)：1951-1960. QU Weiwei，DONG Huiyue，KE Yinglin. Pose accuracy compensation technology in robot-aided aircraft assembly drilling process[J]. Acta Aeronautica ET Astronautica Sinica，2011，32(10)：1951-1960.
[9] 史晓佳，张福民，曲兴华，等. Kuka工业机器人位姿测量与在线误差补偿[J]. 机械工程学报，2017，53(8)：1-7. SHI Xiaojia，ZHANG Fumin，QU Xinghua，et al. Position and attitude measurement and online errors compensation for KUKA industrial robots[J]. Journal of Mechanical Engineering，2017，53(8)：1-7.
[10] 储婷婷. 基于多轴耦合同步控制的机器人高精度轨迹跟踪方法研究[D]. 哈尔滨：哈尔滨工业大学，2015. CHU Tingting. Research on robotic high precision tracking based on multiaxial coupling synchronized control [D]. Harbin：Harbin Institute of Technology，2015
[11] YOUCEF-TOUMI K，LIU W S，ASADA H. Computer- aided analysis of reconfigurable fixtures and sheet metal parts for robotic drilling[J]. Robotics & Computer Integrated Manufacturing，1988，4(3-4)：387-393.
[12] 王运巧，梅中义，范玉青. 薄壁弧形件装夹布局有限元优化[J]. 机械工程学报，2005，41(6)：214-217，223. WANG Yunqiao，MEI Zhongyi，FAN Yuqing，Finite element optimization of machining fixture layout of thin-walled arc workpiece[J]. Journal of Mechanical Engineering，2005，41(6)：214-217，223.
[13] PRABHAHARAN G，PADMANABAN K P，KRISHNAKUMAR R. Machining fixture layout optimization using FEM and evolutionary techniques[J]. The International Journal of Advanced Manufacturing Technology，2007，32(11/12)：1090-1103.
[14] 秦国华，吴竹溪，张卫红. 薄壁件的装夹变形机理分析与控制技术[J]. 机械工程学报，2007，43(4)：211-216，223. QIN GuoHua，WU Zhuxi，ZHANG Weihong. Analysis and control technique of fixturing deformation mechanism of thin-walled workpiece[J]. Journal of Mechanical Engineering，2007，43(4)：211-216，223.
[15] KULANKARA K，MELKOTE S N. Machining fixture layout optimization using the genetical algorithm[J]. International Journal of Machine Tools & Manufacture，2000，40(4)：579-598.
[16] LI B，MELKOTE S N. Fixture clamping force optimization and its impact on workpiece loacation accuracy[J]. Manufacturing Technology，2001，17：104-113.
[17] SUBRAMANIAN V，EDWARD C，De METER，et al. An investigation of effectiveness of fixture layout optimization methods [J]. International Journal of Machine Tools & Manufacture，2002，42：251-263.
[18] KAYA N. Machining fixture locating and clamping position optimization using genetic algorithms[J]. Computers in Industry，2006，57(2)：112-120.
[19] PADMANA K P，ARULSHRI K P. PRABHAKARAN G. Machining fixture layout design using ant colony algorithm based continuous optimization method[J]. The International Journal of Advanced Manufacturing Technology，2009，45(9/10)：922-934.
[20] SUNDARARAMAN K A，GUHARAJA S，PADMANABAN K P，et al. Design and optimization of machining fixture layout for end-milling operation[J]. The International Journal of Advanced Manufacturing Technology，2014，73(5/8)：669-679.
[21] HAO Jiaxuan，WANG Fuji，ZHAO Meng，et al. Drill bit with clip-edges based on the force control model for reducing the CFRP damage[J]. Journal of Reinforced Plastics and Composites，2021，40(5-6)：206-219.
[22] JIA Zhenyuan，FU Rao，NIU Bin，et al. Novel drill structure for damage reduction in drilling CFRP composites[J]. International Journal of Machine Tools and Manufacture，2016，110：55-65.
[23] 贾振元，付饶，王福吉. 碳纤维复合材料构件加工技术进展[J]. 机械工程学报，2023，59(19)：348-374. JIA Zhenyuan，FU Rao，WANG Fuji. Research advance review of machining technology for carbon fiber reinforced polymer composite components[J]. Journal of Mechanical Engineering，2023，59(19)：348-374.
[24] 贾振元，毕广健，王福吉，等. 碳纤维增强树脂基复合材料切削机理研究[J]. 机械工程学报，2018，54(23)：199-208. JIA Zhenyuan，BI Guangjian，WANG Fuji，et al. The research of machining mechanism of carbon fiber reinforced plastic[J]. Journal of Mechanical Engineering，2018，54(23)：199-208.
[25] FENG Pingfa，WANG Jianjian，ZHANG Jianfu，et al. Drilling induced tearing defects in rotary ultrasonic machining of C/SiC composites[J]. Ceramics International，2017，43(1)：791-799.
[26] LIU Yang，LIU Zhibing，WANG Xibin，et al. Experimental study on tool wear in ultrasonic vibration- assisted milling of C/SiC composites[J]. The International Journal of Advanced Manufacturing Technology，2020，107(1-2)：425-436.
[27] GENG Daxi ，ZHANG Deyuan，XU Yonggang，et al. Rotary ultrasonic elliptical machining for side milling of CFRP：tool performance and surface integrity[J]. Ultrasonics，2015，59：128-137.
[28] RUI Xue，BESTLE D. Reduced multibody system transfer matrix method using decoupled hinge equations[J]. International Journal of Mechanical System Dynamics，2021(002)：001.
[29] RUI Xiaoting，ZHANG Jianshu，WANG Xun，et al. Multibody system transfer matrix method：The past，the present，and the future[J]. International Journal of Mechanical System Dynamics，2022，1(1)：002.
[30] RUI Xiaoting，WANG Xun，ZHOU Qinbo，et al. Transfer matrix method for multibody systems (Rui method) and its applications[J]. Science China Technological Science，2019，62(5)：712-720.