鑄件殘料表面加工是目前機器人加工的一大主要應用，然而當鑄件殘料尺寸不同時其所需切削力亦是不同，若使用固定力量伺服控制進行加工則容易發生過切現象造成工件損壞。為此本研究開發一套安裝於固定平台的主動式變力量控制系統針對鑄件殘料毛邊去除進行安全且有效率的半精加工製程。首先當機械手臂所夾持之鑄件依照手臂教導員規劃的加工路徑向刀具進給時，系統會透過機械視覺偵測鑄件殘料資訊並根據切削力模型規劃所需加工力量命令，如此一來系統便能透過變力量伺服控制在刀具進給時移除不同尺寸的鑄件殘料。本研究以5052鋁合金實際加工過程獲得移除不同厚度殘料所需的切削力後，再以最小平方法識別三組線性切削剛性方程並以此作為切削力模型。本研究參考自行車前叉鑄件殘料實際輪廓與加工情境設計多組殘料造型的加工測試件進行變力量加工實驗。實驗結果顯示所開發之主動式變力量控制系統於加工「工件表面為平面」測試件時，可在工件不過切的情況下移除90%以上的殘料；至於加工「工件表面為斜面」的測試件時，則可能因機械手臂自身剛性不足及刀具進刀複雜動態影響而產生過切現象。

Surface machining such as casting scrap removal is an important application for robotic-machining. Because the cutting force varies with the varying size of the machined scraps, it is very easy to cause over-cutting and failed machined workpieces if simply applying constant force servo control to perform scrap machining. To deal with this problem this study develops a variable cutting force control system to improve the safety and efficiency of a semi-finish machining process related to removing casting scraps. When the casting workpiece mounted on the robot manipulator feeds to the cutting tool system mounted on the ground, the scrap size will be measured using machine vision and the required cutting force reference command corresponding to the measured scrap size will be generated using a cutting force model. A variable force servo system which actuates the cutting tool is then implemented to remove casting scraps during the machining process. To verify the effectiveness of the proposed cutting force control system, a set of Aluminum 5052 workpieces whose scrap profiles are based on the casting parts of bicycle front forks are adopted in robotic machining experiments and the cutting force model is approximated as a piecewise linear function that relates the machining stiffness to the scrap thickness. Experimental results demonstrate that 90% total material removal volume percentage is achieved without over-cutting when removing the scraps on a flat plane. However, due to the flexible stiffness of the manipulator and complicated tool feeding dynamics over-cutting may be still occurring when removing the scraps on a slanted plane, which could be further investigated in the future for performance improvement.

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