Assessment of a robot base production using CAM programming for the FANUC control system

Resea ch A icle Pe e Michalik*, Jana Fabiano a, Leopold H abo sky, Ma inko Masla ić, Lubosla S aka and Joze Macej Assessmen o a obo base p oduc ion using CAM p og amming o he FANUC con ol sys em h ps://doi.o g/10.1515/eng-2021-0085 ecei ed June 04, 2021; accep ed July 26, 2021 Abs ac : The subjec o he a icle is he esea ch o he p oduc ion o a obo base using CAM p og amming, Au odesk In en o HSM so wa e, ollowed by he gen- e a ion o G code –NC p og am. The esea ch specifically examined he accu acy o measu emen and e alua ion o oundness wi h coaxiali y on a 3D measu ing de ice Thome. The su ace oughness o he ci cula holes was measu ed using a Mi u oyo SJ 400 oughness me e . The maximum de ia ion o he oundness o he diame e D56H7 measu ed was 0.011 mm, and he diame e D72H7 measu ed was 0.013 mm. The coaxiali y de ia ion o he diame e s D56H7 and D72H7 measu ed was 0.017 mm. Keywo ds: obo , CAM, coaxiali y, oughness, obo base 1 In oduc ion Robo ics is cu en ly es ablished no only in indus y bu also in esea ch labo a o ies. This e m can be used e en in a eas whe e i is inapp op ia e, so knowing exac ly wha he wo d obo means, how i is con olled and how i canbeusedinspecificapplica ionsis e yimpo an . Souza e al. [1]designed a wi eless ligh weigh obo ic a m o eaching pu poses ha se es only o p og am i s pa h wi hou a g ippe . And ou obo ic a m can be used no only o educa ional bu also o indus ial pu poses, handling ligh loads up o 2 kg. Unda e al. [2]in oduced he mos gene al case s udy o he mo emen o a mobile obo wi h obo ic a m. The ou -wheel diffe en ial config- u a ion allows g ea e s abili y o obo ic a m ope a ion. In addi ion, he design allows he inco po a ion o senso s such as ul asonic senso s o in e ac ion wi h obs acles. The buil obo ic a m allows he clamping o pieces o less han 20 g, a a maximum dis ance o 350 mm om he base o he obo ic a m. Beni ez e al. [3]designed and manu- ac u ed a simple obo ic a m o online eaching o s u- den s. Fo compa ison wi h ou obo ic a m, which was p oduced by he chip milling me hod, Beni ez e al. made a ms on a 3D p in e wi h p in ing a ms made o plas ic ma e ials. This me hod o p oduc ion is commonly a ail- able o mos s uden s. Sáenz Zama ón e al. [4]de eloped Educa ional Robo A m, which has ou axes o eedom and is also in ended o educa ional pu poses, howe e . Ou obo ic a m has one less deg ee o eedom. Simila ly, he componen s o ou obo ic a m we e ab ica ed by he chip me hod on a CNC milling machining cen e . Zama ón e al. used Robo ics Toolbox o simula e he con ol o he Ma lab obo ic a m and we a e conside ing he use o LabView so wa e. We also conside he con ol uni A duino. One o he specific applica ions is he use o obo ic wo kplaces in he handling and anspo o a ious p oduc s using ough and hose con eyo s, which a e cu en ly finding inc easing use [6]. The indi idual com- ponen s o he obo s a e also manu ac u ed using CAM p og amming [7]. The obo s a e di ided acco ding o a ious c i e ia. One o hem is he di ision acco ding o kinema ics. The fi s ype is he cylind ical coo dina ion sys em (Figu e 1)[13]. This cons uc ion pe o ms h ee p ima y mo emen s, o which wo mo emen s a e ansla ional and he hi d is o a y. The coo dina ion sys em is no widely ep esen ed in he indus y and wi h a cons uc ion based on a  * Co esponding au ho : Pe e Michalik, Facul y o Manu ac u ing Technologies, Technical Uni e si y o Košice wi h a sea in P ešo , Baye o a 1, 080 01 P ešo , Slo ak Republic, e-mail: [email p o ec ed] Jana Fabiano a: Facul y o Mining, Ecology, P ocess Con ol and Geo echnologies, Technical Uni e si y o Košice, Pa k Komenského 14, 040 01 Košice, Slo ak Republic Leopold H abo sky: Facul y o Mechanical Enginee ing, VŠB- Technical Uni e si y o Os a a, 17. lis opadu 2172/15, 708 00 Os a a -Po uba, Czech Republic Ma inko Masla ić:Facul y o Technical Sciences, Uni e si y o No i Sad, T g Dosi eja Ob ado ica 6, 21000 No i Sad, Se bia Lubosla S aka, Joze Macej: Facul y o Manu ac u ing Technologies, Technical Uni e si y o Košice wi h a sea in P ešo , Baye o a 1, 080 01 P ešo , Slo ak Republic Open Enginee ing 2021; 11: 922–928 Open Access. © 2021 Pe e Michalik e al., published by De G uy e . This wo k is licensed unde he C ea i e Commons A ibu ion 4.0 In e na ional License. cylind ical sys em o mo emen s, i is used o p imi i e asks, such as spo welding, o as a simple manipula o . The obo nodes a e inspec ed by he fini e elemen me hod [5]no only o he magni ude o he s ess bu also o he magni ude o he de o ma ion [8].P io o ac ual p oduc ion o some obo componen s, he p ope ies o he ma e ials a e also checked [11]. In addi- ion o con en ional machining echnologies, wa e je machining is used o p oduce some obo componen s [10], while i is also necessa y o con ol he quali y o he machined su ace [12]. A he s a ing poin , he con- ol uni is ins uc ed o s a he mo o s in he o de specified by he p og am un il he posi ion equi ed o each he end poin posi ion is eached. The whole cycle is epea ed ei he immedia ely a e eaching he s a ing poin o a e ins uc ing a ime o a pulse om he senso –came as [9]. 2 Robo base Robo base in Figu e 2 shows ha 3D model is one o he pa s o he obo assembly, i o ms he base o he obo , he e o e i s design paid a en ion o i s igidi y and load- bea ing capaci y and i s dimensions we e chosen on he basis o hese equi emen s. The base o he obo houses a gea box wi h a se omo o , which pe o ms a o a y mo emen o he a m ins alled on he base. High emph- asis is placed on moun ing he gea box in he obo base. I s moun ing mus be as p ecise as possible in o de o p e en o minimize de ia ions o he a m o a ional mo emen . The gea box is housed in ole a ed holes D56H7 and D72H7. The placemen o H7 a a gi en dimen- sion ep esen s a hole ole ance o 0.015 mm. To p oduce hese ole a ed dimensions, a eaming ope a ion wi h a bo ing ba was chosen. 2.1 P ocedu e o obo base p og amming and p oduc ion Fo p og amming he p oduc ion o ole a ed dimensions o he obo base, he d awing documen a ion in Figu e 3 wi h a oughness R z o 12.5 μm, made o Al4.5MgMn ma e- ial, was documen ed. The ools used o p oduce ole - a ed holes we e as ollows: •Face d ill 880-D4100C6-03, Figu e 1: Cylind ical coo dina ion sys em o a obo [13]. Figu e 2: 3D model o a obo base. Assessmen o a obo base p oduc ion using CAM p og amming 923 •Ca bide 4 –pla e cu e wi h a diame e o Ø 20 mm, and •ISCAR BHF-MB50-80 bo ing ba . Machining was designed in he CAD/CAM p og am Au odesk In en o HSM. The oughened base o he obo was clamped o he wo k able using ou clamps. The fi s s ep in p og amming he machining o he obo base was o selec he size o he semi-finished p oduc and se i s ze o alue (Figu e 4). The ze o poin was selec ed in he middle o he cylind ical pa o he obo base wi h a diame e o D140 mm. This was ollowed by d illing and se ing he cu ing condi ions o he defined d illing cycle (Figu e 5). A d ill bi wi h a diame e o D41 mm unde ype designa ion 880-D4100C6-03 was used o d illing. The d illing dep h was 15 mm. A e d illing a D41 mm hole, an adap i e milling ope a ion was pe o med using a ca bide ou - pla e cu e wi h a diame e o D20 mm. In his machining s a egy, he cu e was plunged o a dep h o 4 mm and he hole D41 mm was enla ged o a diame e o D72 mm wi h he addi ion o 0.3 mm. The o e all dimension o he hole p oduced was D71.7 mm. An allowance o 0.3 mm was chosen o he las eaming ope a ion when he final dimension o he hole is made o ole ance H7, which means ha he hole has a dimension o D72.015 mm (Figu e 6). Du ing p og amming, a eaming cycle was selec ed in which a ool was defined –a bo ing ba , he cons uc- ion o which allows you o se diame e s by one hun- d ed h o a millime e . The 3-axis e ical machining cen e Pinnacle VMC 650S was chosen o p oduce he obo base. Figu e 7 shows hole milling on he Pinnacle VMC 650S. The machining cen e is con olled by he FANUC con ol sys em. The p ocedu e o p oduce a hole wi h he diame e o Ø 56 H7 is he same as o he p oduc ion o a hole Ø 72 H7. Figu e 3: P oduc ion d awing o a obo base. Figu e 4: Se ing o ze o poin o he obo base. 924 Pe e Michalik e al. 3 Resul s The p oduc ion o ole a ed dimensions was ollowed by measu emen s in which he su ace oughness o he indi idual holes, he oundness and he coaxiali y o he holes we e de e mined. The su ace oughness was measu ed using a Mi u oyo SJ 400 oughness me e (Figu e 8). The measu emen s we e epea ed 11 imes. The esul s o measu emen s o indi idual holes a e shown in he g aphs in Figu es 9 and 10. The ollowing alues we e ound by measu emen : hole D56H7 highes alue o su ace oughness R a = Figu e 5: Se ing o cu ing pa ame e s. Figu e 6: Defining o adap i e milling pa ame e s. Assessmen o a obo base p oduc ion using CAM p og amming 925 1.01 μm, R z =8.4 μm. The lowes su ace oughness R a was 0.58 μm and he lowes R z alue was 3.6 μm. Fo a hole wi h dimension D72H7, he highes su ace ough- ness was R a =1.08 μm and R z =9.2 μm. The lowes su ace oughness R a was 0.57 μm and R z was 3.8 μm. Ano he measu ed pa ame e was he oundness and coaxiali y o he holes. These pa ame e s we e measu ed on a 3D measu ing de ice o he Thome ype. Figu e 11 shows he measu emen o hese pa ame e s. Figu e 12 shows he assembled obo base wi h obo ic a m 1, gea box and ac ua o . The quali y o he machining p ocess was e alua ed using he p ocess capabili y index C P , which is defined by he ollowing ela ion:=− C σ USL LSL 6, P(1) whe e USL is he uppe specifica ion limi , LSL is he lowe specifica ion limi and σis he s anda d de ia ion o he p ocess. Fo diame e 56H7 he alue o C P =0.56 and o diame e 72H7 he alue o C P =0.74. Figu e 7: Hole milling on he Pinnacle VMC 650S. Figu e 8: Measu emen o he su ace oughness o he hole D56H7. Figu e 10: Roughness o he hole su ace wi h diame e D72H7. Figu e 9: Roughness o he hole su ace wi h diame e D56H7. 926 Pe e Michalik e al. 4 Conclusion The p oposed me hod o p oduc ion o he obo base was ealised on a h ee-axis machining cen e Pinnacle VMC 650S. The quali y o machining was e ified using he p ocess capabili y index C P . The CAD/CAM p og am Au odesk In en o HSM was used o CAM p og amm- ing. Cylind ical holes wi h diame e s D56H7 and D72H7 we e made in h ee ope a ions: d illing, adap i e milling– punching and eaming. The esul o measu ing he ound- ness o he hole D56H7 was 0.011 mm, and o he hole D72H7 i was 0.013 mm. The coaxially de ia ion be ween holes D56H7 and D72H7 was 0.017, which mee s he equi ed ole ance o gi en dimensional ange. A e e al- ua ing hese esul s, we can conclude ha he chosen me hod o p oduc ion and measu emen o he obo base allows you o c ea e he equi ed assembly along wi h a ecommenda ion o p oduc ion o o he obo componen s. Acknowledgmen s: This wo k is a pa o esea ch p ojec VEGA 1/0045/18 and SK-SRB-18-0053. Conflic o in e es : Au ho s s a e no conflic o in e es . Re e ences [1]Souza MR, Ta a es JJ, Ribei o JF, Rocha RR. Design, manu ac u e and cons uc ion o a wi eless obo ic a m o educa ional pu - poses. [In e ne ]. 2015 12 h La in Ame ican Robo ics Symposium and 2015 3 d B azilian Symposium on Robo ics (LARS-SBR). Ube landia, B azil: IEEE; 2015 [ci ed 2021 July 9].p.376–80. doi: 10.1109/LARS-SBR.2015.68. [2]Unda OF, He nandez W, Va gas O, Mendez A, Se giyenko O, Ty sa V. 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