Robotic Drilling of Aluminum Alloy

This paper presents an experimental approach to evaluate the ability of a six-axis industrial robot to drill aluminum alloy parts. A strategy based on statistical tests has been studied to quantify and predict the relative contribution of cutting parameters on cutting force and shape errors during drilling. This technique is based on the identification of relevant sources of error during high-speed robotic fitting. The machining quality was quantified in terms of dimensional and geometric tolerance, chip formation and evacuation, burr formation, edge build-up, tool wear and surface damage. Statistical analysis of the experimental results reveals a strong dependence between part accuracy and drilling force. An experimental model was developed to represent and predict the cutting force during drilling and an accurate error prediction capability was distinguished. It was found that at high cutting speed and feed rate, the cutting force was the main source of error affecting the accuracy of the machined parts. Verification experiments are performed, and the results reveal that dimensional defects are significantly reduced by a heat treatment effect (90 HRE) and the thrust force decreases with an increase in cutting speed. The recommended cutting speed for robotic drilling is 6000 rpm with a feed rate of 0.15 mm/min. This study provides important technical guidance for improving the robotic drilling of aluminum alloy in practice.