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Full Length Article | Open Access

Chatter stability of robotic rotary ultrasonic countersinking

Zhenwen SUNa, Wenhe LIAOa,( ), Kan ZHENGa, Song DONGa, Pei LEIb, Lianjun SUNa
School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing 210094, China
Chengdu Aircraft Industrial (Group) Co., Ltd., Chengdu 610091, China

Peer review under responsibility of Editorial Committee of CJA.

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Abstract

In recent years, industrial robots have received extensive attention in manufacturing field due to their high flexibility and great workspace. However, the weak stiffness of industrial robots makes it extremely easy to arouse chatter, which affects machining quality inevitably and generates noise pollution in severe cases. Compared with drilling, the chatter mechanism of robotic countersinking is more complex. The external excitation changes with cutting width and depth in countersinking. This characteristic results in time-varying and nonlinearity of robotic countersinking dynamics. Thus, it is urgent to propose a new method of chatter suppression and provide an accurate stability analysis model. As a new special machining technology, rotary ultrasonic machining has been proved to improve robotic drilling and milling stability effectively. Based on this, robotic rotary ultrasonic countersinking (RRUC) is proposed to improve the robotic countersinking stability in this paper. A three-dimensional stability domain method of RRUC is established. First, the countersinking process was divided into ρ parts. The dynamic model of every unit was constructed based on ultrasonic function angle (γ) and dynamic chip area. Then, the stability region of RRUC is obtained based on the semi-discrete method (SDM). Compared with the robotic conventional countersinking (RCC), RRUC improves the stability by 27%. Finally, the correctness and effectiveness of the stability region model are proved by robotic ultrasonic countersinking experiments.

Keywords

Dynamic modelStability analysisIndustrial robotRotary ultrasonic machiningCountersinking chatter

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Chinese Journal of Aeronautics
Volume 36 Issue 10,
October 2023
Pages 434-444
DOI: 10.1016/j.cja.2023.03.022
Cite this article:
SUN Z, LIAO W, ZHENG K, et al. Chatter stability of robotic rotary ultrasonic countersinking. Chinese Journal of Aeronautics, 2023, 36(10): 434-444. https://doi.org/10.1016/j.cja.2023.03.022

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Received: 02 September 2022
Revised: 08 October 2022
Accepted: 13 December 2022
Published: 16 March 2023
© 2023 Chinese Society of Aeronautics and Astronautics.

This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
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