Automated polishing of machine tools
Since the Industrial Revolution, the use of machines to do work has advanced manufacturing exponentially. However, producing the machine tools to do that work still relies partly on manual labour. Machine tools are largely made using dies and moulds, structures with special geometries that form materials into complex shapes. The final process in machine tool manufacturing is finishing — polishing of the component’s surface to make it smooth and non-abrasive. Increasing complexity of machine tools require time- and cost-intensive hand polishing to finish freeform surfaces with function-relevant edges. In fact, more than 10 % of manufacturing costs and between 30 and 50 % of manufacturing time are devoted to finishing. Automated laser polishing and force-controlled robot polishing have been successful in the finishing of flat surfaces. These have not yet been applied to freeform surfaces due to technical difficulties. A European consortium changed the rules of the game with EU funding of the 'Automated polishing for the European tooling industry' (POLIMATIC) project. Process strategies for both of the selected processes were developed. The team enhanced machine technology for laser polishing and developed new algorithms for programming the robot as well as simulation software for robotic polishing. Scientists also developed standardised methods of measurement of surface roughness to be used both in optimisation of processes and also in metrology-assisted manual polishing. POLIMATIC has turned laser polishing and robotic polishing into reliable manufacturing processes. Technology will provide a major breakthrough in machine tool manufacturing, enabling widespread automation of the time-consuming and costly manual finishing of freeform machine tools. In addition to enhancing the competitiveness of the European tooling industry, Polimatic technology could find broad application in other industrial sectors. These include medical implants and devices, engine parts and valve components, to name only a few.
Keywords
Machine tools, automated, polishing, finishing, freeform, laser, algorithm, robot, simulation, metrology