Robotik Elektrokimyasal İşleme Yönteminde İçbükey ve Dışbükey Parçaların İşlenebilmesi için Uç İşlevci Tasarım

Abstract

Uzay ve havacılık sanayinde kullanılan işlenmesi zor malzemelerin geleneksel imalat yöntemleriyle işlenmesinde takım aşınması, artık stres ve termal gerilme gibi sınırlamalar mevcuttur. Bu sınırlamaların aşılabilmesi için birçok farklı alışılmamış imalat yöntemi tercih edilmektedir. Hibrit bir yöntem olan robotik elektrokimyasal işleme (REKİ) metodu da bu yöntemlerden biridir. REKİ temassız bir işleme yöntemi olduğu için işleme sonrası düşük yüzey pürüzlülüğü elde edilmektedir. Ancak robot kolun nispeten düşük olan hareket doğruluğundan dolayı işleme performansı olumsuz etkilenmektedir. Bu çalışma REKİ yönteminin verimliliği arttırmak amacıyla robot kola bağlı bir tutucu mekanizmasının tasarımını ve optimizasyonunu sunmaktadır. Bu mekanizma gövde, çeneler, elektrolit transfer sistemi ve hareket sistemi olmak üzere 4 ana unsurdan oluşmaktadır. Tutucu mekanizmasının işleme performansının değerlendirilmesi amacıyla işleme süresinin kritik proses parametresi olduğu bir dizi deney yapılmıştır. Bu deneyler sonucunda işleme süresinin artmasıyla malzeme işleme hızının (MİH) arttığı ve MİH değerindeki artışın yüzey pürüzlülüğünü olumlu etkilediği gözlemlenmiştir. Faraday Yasaları’nı ve literatürü destekler nitelikte elde edilen bu sonuçlar ışığında geliştirilen uç işlevcinin kullanılmasıyla REKİ yönteminin MİH ve yüzey pürüzlülüğü değerlerini sırasıyla 55.14% ve 35.57% oranında arttırıldığı gözlemlenmiştir. 

Keywords

• Uç işlevci
• Robotik elektrokimyasal işleme
• İç bükey
• Dış bükey
• Tasarım

Design and Optimization of End Effector for Machining Concave and Convex Parts in Robotic Electrochemical Machining

Abstract

In the machining of the difficult to cut materials used in aerospace and defense industry with traditional manufacturing methods, limitations such as tool wear, residual stress and thermal stress are encountered. To overcome these limitations, many non-traditional manufacturing methods are preferred. Robotic electrochemical machining (RECM) is one of these non-traditional manufacturing methods and is considered a hybrid process. As RECM is a non-contact machining method, a low level of surface roughness is achieved after machining. However, the relatively low accuracy of the robot arm movements is a negative impact on machining performance. This study presents the design and optimization of an end effector mechanism connected to a robotic arm in order to increase the efficiency of the RECM method. This mechanism consists of four major elements as body, jaws, electrolyte transfer system and movement system. In order to evaluate the machining performance of the end effector mechanism, a series of experiments were conducted in which the machining time was the critical parameter. The experimental results show that the material removal rate (MRR) increases as the machining time rises, and this situation positively affects the surface roughness. In the light of these results, which support Faraday's laws and the literature, it was observed that the MRR and surface roughness values of the RECM method were increased by 55.14% and 35.57%, respectively, by using the end effector mechanism.

Keywords

• End effector
• Robotic electrochemical machining
• Concave
• Convex
• Design

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