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CSME 2025/10
Volume 46 No.5
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495-505
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Robot-Assisted Surface Finish of STAVAX Mold Steel with Constant Force Control Using Lab-Made Polishing Tools
Fang-Jung Shiou a, Chang-Mou Wu b, Wei-Yu Shih c and Bo-Yu Chen c
aProfessor, Department of Mechanical Engineering, National Taiwan University of Science and Technology, Taipei, Taiwan 106335, ROC.
bProfessor, Department of Material Science and Engineering, National Taiwan University of Science and Technology, Taipei, Taiwan 106335, ROC.
cGraduate Student, Department of Mechanical Engineering, National Taiwan University of Science and Technology, Taipei, Taiwan 106335, ROC.
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Abstract:
The automated precision surface finishing processes are the demanding technologies to be developed, to improve some drawbacks of manual polishing. The objective of this study is to develop robot assisted constant force polishing of STAVAX mold steel using lab-made polishing tools mounted on a new polishing end effector. A new polishing end effector embedded with a force sensor has been designed and fabricated, so constant force polishing was possible on a 6-axis industrial robot. The Taguchi method was applied to determine the optimal polishing parameters of the new polishing tools for the STAVAX mold steel. For flat plane polishing using a cylindrical polishing tool with a diameter of 40 mm, the appropriate parameters were the particle size of 0.3 μm, a rotation speed of 5,600 rev/min, a feed rate of 0.1 mm/min, and a polishing force of 6 N. The PID controller has been adopted in this work for constant force polishing. The control gains of Kp, Ki, and Kd of the PID controller were investigated by polishing experiments for different polishing tools. The optimal polishing parameters were applied to both the flat and freeform surfaces of a test carrier. Based on the experimental results, the surface roughness of the plane area was improved from Ra 0.36 μm to Ra 0.02 μm after sequential burnishing and polishing. For a freeform surface area, the surface roughness of the burnished test carrier was reduced from Ra 0.18 μm to Ra 0.04 μm on average after ball polishing.
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Keywords: six-axis industrial robot, polishing tool, constant force polishing, PID control, Taguchi method, STAVAX mold steel.
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©
2025
CSME , ISSN 0257-9731
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