Grant: Discovery Grants Program - Individual

The use of robots as cutting tool holders to remove material from metal parts is recognized as an effective and flexible approach for an increasing number of industrial applications. Robot-based machining systems have been successfully used for the repair of hydroelectric equipment and are also an interesting alternative solution for automating various processes in the field of mechanical and aerospace manufacturing. Robotic machining offers several advantages compared to conventional computer numerical control (CNC) machining. Robotic machining systems are not only more flexible, manoeuvrable and less expensive to operate, they can also save up to 40% in production workspace compared to industrial CNC machining centers. Robotic machining is also more suitable in hazardous working conditions to replace human operators. This program proposes a new robotic machining strategy using two hexapods for collaborative robotic machining operations. The main objective is to investigate the dynamics of the proposed robotic machining processes, to optimize the tool path and cutting parameters for feature machining of planar and curved surfaces and to propose a process monitoring approach. This research program is intended to increase the level of manufacturing readiness of the robotic machining. Within the scope of the proposed research program, we will study the feasibility of a new collaborative machining approach/architecture using two hexapods. We propose to model and study the dynamics of the collaborative robotic system, the material removal mechanism, and the linear and nonlinear chatter vibration problems associated with the machining process. Vibration control algorithms will be proposed to stabilize robotic machining operations and thereby increase the productivity and quality of the process. Moreover, a new process monitoring approach applied to the robotic machining process will be developed and implemented using wireless instrumented embedded force sensors for online control of the robotic machining. Regarding the hardware configuration, we propose a new build up using two hexapods. This set-up is expected to offer an increased dexterity for the machining of complex parts and easier design of tool path for chatter-free and singularity-free configurations by moving both end-effectors simultaneously and cooperatively. The originality of this research proposal lies in the development of a novel collaborative machining system using parallel robots, an active vibration control strategy and an online monitoring system using embedded sensors for robotic machining. This research will provide contributions for the development of flexible and reconfigurable manufacturing systems and increase the application versatility of robots in industrial automation.