Prediction of the tool displacement for robot milling applications using coupled models of an industrial robot and removal simulation

Industrial robots are used in a great variety of applications for handling, welding and milling operations. They represent a cost-saving and flexible alternative for machining applications. A reduced pose and path accuracy, especially under process force load due to the high mechanical compliance, restrict the use of industrial robots for further machining applications. In this paper a method is presented to predict the resulting path deviation of the robot under process force. A process force simulation based on a material removal calculation is proposed. The presented material removal simulation allows the calculation of the chip geometry even in complex cutter work piece engagement conditions. The removal simulation is validated by means of conducted milling tests. By coupling the removal simulation with a robot model the path deviation can be predicted.