Dynamic and dimensional evaluation of robot applications in the drilling process in Al–Mg-Si 6351 T6 aluminum alloy
摘要
Competitiveness inherent to global markets shows the need to develop and manufacture high-quality products at a low cost. The automobile industry shows this scenario well as it is significantly relevant in the global economy. Applying the most recent technologies in manufacturing processes is a productive field that favors the development of studies and research in the field of Engineering. Most automobile manufacturers integrate powertrain machining of rotational and prismatic components into their manufacturing process where tolerance and surface finish requirements are very low. In recent years, these requirements have been achieved using computer numerical control (CNC) machine tools and the development of material technology. As the drilling process in aluminum alloys is a relevant step in machining the mentioned components, this article evaluates the application of anthropomorphic robots in drilling in Al–Mg-Si 6351 T6 aluminum alloy. Robotic drilling applications can bring advantages such as flexibility, maneuverability and cost competitiveness, although problems related to dynamics and rigidity make their application challenging. This work evaluated the dynamic, dimensional, geometrical conditions, and tolerances found in the robotic drilling process in Al–Mg-Si 6351 T6 alloy. CAD, CAT, and CAE (multibody) modeling were the basis for manufacturing a robotic cell and contributed to planning with assertiveness (90%) when compared to the physical one. The average diameters of the holes, position error in the coordinates, cylindricity, and circularity presented values in the order of hundredths of millimeters, while the perpendicularity errors obtained were in the order of thousandths of millimeters. The surface finish (Ra) of the holes presented an acceptable average compared to conventional machining processes (3.09 μm), and it was observed that the results can be attenuated by 20% through robot posture optimization.