Unconventional and Robotic Manufacturing

Cell

Unconventional and Robotic Manufacturing

UNCONVENTIONAL AND ROBOTIC MANUFACTURING CELL

 

Integration of industrial robotics with conventional and unconventional manufacturing processes leads the way to establish reconfigurable, cost-effective manufacturing systems enabling hybrid-manufacturing concepts.

SU-IMC utilizes Robotic Automated Fiber Placement (AFP) for composite manufacturing, Robotic Machining and Abrasive Waterjet Machining of composites and metals, and Additive Manufacturing of composites. SU-IMC aims to demonstrate the use of reconfigurable manufacturing systems to SMEs and OEMs together with their cost and performance benefits. SU-IMC investigates the simulation, development and application of robotic manufacturing processes encompassing both science and engineering aspects.

 

 

The robotic machining and additive manufacturing cell can process both metals, plastic and thermoset composites, and metal matrix composites. The target industries are aerospace, automotive, sports equipment and yachting. The system can accommodate two working tables and two industrial robots integrated with corresponding processing end effectors for 3-axis and 5-axis processing of metal and composite parts.

The robotic Abrasive Waterjet Machining cell can process metals and composites for both through thickness and controlled depth 5-axis machining purposes. AFP process is carried out with robotic system installed on a rail.

 

 

OUTPUTS

The Advanced Composites Manufacturing Lab aims to develop novel robotic manufacturing technologies through process modelling to explain process-robot interaction, robot motion and path planning using physical models.

 

 

TARGET SECTORS/AREAS

SU-IMC aims to demonstrate robotic manufacturing processes primarily for Aerospace Industries in production of composite and metallic materials such as mold lay-up, machining of composites, and rough machining of difficult to cut materials such as Ni & Ti alloys. The application area may be extended to rough machining of large scale dies and molds used in automotive body production.

 

 

EQUIPMENTS

The lab has below equipment as manufacturing systems

 

Robotic Hybrid Manufacturing Cell

Both robots can work with G-codes and Robot codes through KUKA CNC.

Machining Robot: KUKA KR240 R2900 Ultra F

Spindle: 24000 rpm, 18 kW, 20 Nm

Wireless probing for accurate part positioning

Additive Robot:  KUKA KR120 R2700 extra HA

 

Robotic AWJ Cell

KUKA KR16 ULTRA-F over hanged on a 3-meter rail.

Work table with dimensions of 2.5m x 2.5m

KMT waterjet pump with 3800 bar pressure

 

Robotic AFP Cell

KUKA QUANTEC KR210 R3100 robot moving on Güdel 8 meter linear axis. The robot can work with molds up to 6 meter long and 3 meters in diameter.