Compliance error compensation in robotic-based milling

TL;DR

This paper presents a detailed nonlinear stiffness model for compensating compliance errors in robotic milling, considering tool, process, and material properties, to improve accuracy and reduce chattering.

Contribution

It introduces a novel nonlinear stiffness-based compensation method that accounts for detailed interaction factors in robotic milling, unlike previous constant-force assumptions.

Findings

Effective error compensation demonstrated on aluminum alloy milling

Nonlinear model reduces chattering effects

Improves milling accuracy in robotic applications

Abstract

The paper deals with the problem of compliance errors compensation in robotic-based milling. Contrary to previous works that assume that the forces/torques generated by the manufacturing process are constant, the interaction between the milling tool and the workpiece is modeled in details. It takes into account the tool geometry, the number of teeth, the feed rate, the spindle rotation speed and the properties of the material to be processed. Due to high level of the disturbing forces/torques, the developed compensation technique is based on the non-linear stiffness model that allows us to modify the target trajectory taking into account nonlinearities and to avoid the chattering effect. Illustrative example is presented that deals with robotic-based milling of aluminum alloy.