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­An Experimental Investigation of Hybrid Position/Force Control for Metal Spinning Process


Abstract: This study is an experimental investigation to implementation of sensor assisted automatic control on the Metal Spinning Processes. Spinning is a sheet metal forming process which a metal discos deformed into contact w­ith a rotating mandrel by axial or axial-¬radial motions of a tool or roller­s. Th­is process plays an important role in metal precision processing fields, such as aeronautics and astronautics. Successful forming of sheet metals using Spinning process, except that authentic tool path and speeds, mainly depends on orientation and size of applying forming forces. Thus for automation of this processes, forming forces are important parameters from view point of control. There are a few works about applying force control methods on the manufacturing processes. One of the pioneer works is applying robot control techniques such as force feedback control on Metal Spinning Processes. The other work was development of nonlinear integrating on/off force controller on an open architecture axis controller CNC lathe. The final goal of this paper is traversing of desired tool path in Metal Spinning Process so the normal force maintained in a constant desired value. This paper presents some overviews of basic strategies that have been proposed for force control of robot manipulators which are suitable for applying on Metal Spinning Processes. From combination of classical control theories such as PID controllers with above mentioned force control strategies, several results have been obtained. These results is compared with each other theoretically and experimentally to determine the suitable controller performance. Also the results are compared from viewpoints of spun part. For the reason of system control, the dynamic model of plant to be controlled is experimentally identified. To implement the Metal Spinning Process, a stepper motor in radial direction, a linear encoder and micro switches is mounted on manual Lathe Machine to transform it to an axial CNC Lathe Machine. Further, a tool post equipped with metal spinning roller tool, is designed and manufactured. An external P4 computer issued to receive position feedbacks from encoder via an A/D input/output card .Also the commanded signals was sending to system via this card. For force control, a six dimensional Dynamometer was interfaced to PC via high resolution 16 channel Data Acquisition Card. A program has been developed in MATLAB for interfacing the user with PC, to control and analyze of the process. ­

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