Towards an automated polishing system: capturing manual polishing operations

Advancements in robotic and automation industries have influenced many manual manufacturing operations. With a great level of success, robots have taken over from man in many processes such as part manufacturing, transfer and assembly. However, in other traditionally manual operations such as polishing, automation has only partially been successful, typically limited to parts with simple geometry and low accuracy. Automated polishing systems using robots have been attempted already by a number of industrial and research groups; however, there are few examples of deploying such a system as a part of a routine production process in high-technology industries, such as aerospace. This is due to limitations in flexibility, speed of operation, and inspection processes, when compared with manual polishing processes. The need for automated polishing processes is discussed in this article and the problem with the existing system was explained to be a lack of understanding and the disconnect from manual operations. In collaboration with industrial partners, a mechatronic based data capturing device was developed to accurately capture and analyze operational variables such as force, torque, vibration, polishing pattern, and feed rates. Also reported in this article is a set of experiments carried out to identify the polishing parameters that a manual operator controls through tactile and visual sensing. The captured data is interpreted to the operators’ preferences and polishing methods and should then be included in the design of an automated polishing system. The research results reported in this article are fed back to an ongoing research project on developing an integrated robotic polishing system

Design, Analysis, Optimization and Control of Rotor Tip Flows

Developments in turbomachinery focus on efficiency and reliability enhancements, while reducing the production costs. In spite of the many noteworthy experimental and numerical investigations over the past decades, the turbine tip design presents numerous challenges to the engine manufacturers, and remains the primary factor defining the machine durability for the periodic removal of the turbine components during overhaul. Due to the hot gases coming from the upstream combustion chamber, the turbine blades are subjected to temperatures far above the metal creep temperature, combined with severe thermal stresses induced within the blade material. Inadequate designs cause early tip burnouts leading to considerable performance degradations, or even a catastrophic turbine failure. Moreover, the leakage spillage, nowadays often exceeding the transonic regime, generates large aerodynamic penalties which are responsible for about one third of the turbine losses. In this view, the current doctoral research exploits the potential through the modification and optimization of the blade tip shape as a means to control the tip leakage flow aerodynamics and manage the heat load distribution over the blade profile to improve the turbine efficiency and durability

Aeronautical engineering: A continuing bibliography with indexes (supplement 276)

This bibliography lists 705 reports, articles, and other documents introduced into the NASA scientific and technical information system in Feb. 1992. Subject coverage includes: design, construction, and testing of aircraft and aircraft engines; aircraft components, equipment, and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics

Aeronautical engineering: A continuing bibliography with indexes (supplement 291)

This bibliography lists 757 reports, articles, and other documents introduced into the NASA scientific and technical information system in May. 1993. Subject coverage includes: design, construction and testing of aircraft and aircraft engines; aircraft components, equipment, and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics

Development of an integrated robotic polishing system

This thesis presents research carried out as part of a project undertaken in fulfilment of the requirements of Loughborough University for the award of Philosophical Doctorate. The main focus of this research is to investigate and develop an appropriate level of automation to the existing manual finishing operations of small metallic components to achieve required surface quality and to remove superficial defects. In the manufacturing industries, polishing processes play a vital role in the development of high precision products, to give a desired surface finish, remove defects, break sharp edges, extend the working life cycle, and meet mechanical specification. The polishing operation is generally done at the final stage of the manufacturing process and can represent up to a third of the production time. Despite the growth automated technology in industry, polishing processes are still mainly carried out manually, due to the complexity and constraints of the process. Manual polishing involves a highly qualified worker polishing the workpiece by hand. These processes are very labour intensive, highly skill dependent, costly, error-prone, environmentally hazardous due to abrasive dust, and - in some cases - inefficient with long process times. In addition, the quality of the finishing is dependent on the training, experience, fatigue, physical ability, and expertise of the operator. Therefore, industries are seeking alternative solutions to be implemented within their current processes. These solutions are mainly aimed at replacing the human operator to improve the health and safety of their workforce and improve their competitiveness. Some automated solutions have already been proposed to assist or replace manual polishing processes. These solutions provide limited capabilities for specific processes or components, and a lack of flexibility and dexterity. One of the reasons for their lack of success is identified as neglecting the study and implementing the manual operations. This research initially hypothesised that for an effective development, an automated polishing system should be designed based on the manual polishing operations. Therefore, a successful implementation of an automated polishing system requires a thorough understanding of the polishing process and their operational parameters. This study began by collaborating with an industrial polishing company. The research was focused on polishing complex small components, similar to the parts typically used in the aerospace industry. The high level business processes of the polishing company were capture through several visits to the site. The low level operational parameters and the understanding of the manual operations were also captured through development of a devices that was used by the expert operators. A number of sensors were embedded to the device to facilitate recording the manual operations. For instance, the device captured the force applied by the operator (avg. 10 N) and the cycle time (e.g. 1 pass every 5 sec.). The capture data was then interpreted to manual techniques and polishing approaches that were used in developing a proof-of-concept Integrated Robotic Polishing System (IRPS). The IRPS was tested successfully through several laboratory based experiments by expert operators. The experiment results proved the capability of the proposed system in polishing a variety of part profiles, without pre-existing geometrical information about the parts. One of the main contributions made by this research is to propose a novel approach for automated polishing operations. The development of an integrated robotic polishing system, based on the research findings, uses a set of smart sensors and a force-position-by-increment control algorithm, and transpose the way that skilled workers carry out polishing processes

Bibliography of Lewis Research Center Technical Publications announced in 1991

This compilation of abstracts describes and indexes the technical reporting that resulted from the scientific engineering work performed and managed by the Lewis Research Center in 1991. All the publications were announced in the 1991 issues of STAR (Scientific and Technical Aerospace Reports) and/or IAA (International Aerospace Abstracts). Included are research reports, journal articles, conference presentations, patents and patent applications, and theses

Aeronautical engineering: A continuing bibliography with indexes (supplement 323)

This bibliography lists 518 reports, articles, and other documents introduced into the NASA scientific and technical information system in November 1995. Subject coverage includes: design, construction and testing of aircraft and aircraft engines; aircraft components, equipment, and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics

Aeronautical engineering: A continuing bibliography with indexes (supplement 268)

This bibliography lists 406 reports, articles, and other documents introduced into the NASA scientific and technical information system in July, 1991. Subject coverage includes: design, construction and testing of aircraft and aircraft engines; aircraft components, equipment and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics