Analysis of robot system capabilities in machining of full scale prototypes for sanitary ware industry

The present paper reviews the potential for applying a CNC robot system to advanced machining techniques, with the aim of optimising company resources in the early stages of new product development. Due to the large dimensions of the robot working envelope, it is possible to totally machine large prototypes at full scale. The experimental work was based on the normal process of model generation through CAD geometric design and CAM toolpath creation, but with subsequent production through robotics CNC machining. The research was undertaken with the objective of characterising the most adequate model materials, tools, and process variables for the rapid machining of prototypes on a CNC robot system at full scale. Initially, the analysis focused on a 3-axis CNC machining operation. With the information achieved in this first stage of the investigation, it was possible to demonstrate the relative importance of adopting 5-axis and high speed CNC machining operations. The research confirms the great advantages attained through this more advanced approach to the industrial production of prototypes. Topics identified for further work are described. BCT/375 At the time the work was carried out Dr Coole was in the School of Engineering and Advanced Technology, PO Box 333, Beaconside, Stafford ST18 ODF, UK. His present address is the Faculty of Technology, Buckinghamshire Chilterns University College, Queen Alexandra Road, High Wycombe, Buckinghamshire HP 11 2JZ, UK. Dr Cheshire is in the School of Engineering and Advanced Technology, PO Box 333, Beaconside, Stafford ST18 ODF, UK. Dr Mesquita is in the Instituto Superior Tecnico, Universidade Tecnica de Lisboa, Portugal. Dr Simoes is in the Escola Superior de Tecnologia, Instituto Politecnico de Setubal, Portugal. Manuscript received 2 March 1999; infinal form 12 April 2000.