Coordinated kinematic modelling for motion planning of heavy-duty manipulators in an integrated open-die forging centre

Abstract An integrated open-die forging centre can realize programmed incremental forging processes to improve safety and efficiency; the centre consists of a forging press and one or two heavy-duty manipulators. This paper focuses on the coordinated kinematic modelling of the integrated system. First a newly designed serial—parallel forging manipulator is presented and the closed-form inverse kinematic solution is derived based on homogeneous co-ordinate transformation. Then the deformation of the forged workpiece is investigated by the spread coefficient method of plastic deformation theory, and the relation between the motion of the holding end of the workpiece and the movement of the upper die is formulated. Finally, the coordinated kinematic modelling of the integrated system is established, where the press and the manipulator are coordinated in movement. Simulation of a typical open-die forging process shows that the gripper of the manipulator should have good compliance abilities in horizontal and vertical directions during forging; however, it should have high rotation stiffness with respect to the transverse axis. The automatic programmed forging plan and coordination control strategy can be pre-designed based on this model.

[1]  F H Osman,et al.  Investigation into the automation of incremental forming processes , 1999 .

[2]  Bangchun Wen,et al.  Simulated comparison on kinematics properties of two typical mechanisms of forging manipulator , 2007, ICMIT: Mechatronics and Information Technology.

[3]  Alan N Bramley,et al.  Upper-bound analysis for the automation of open-die forging , 1997 .

[4]  J Tajima,et al.  Optimization of open-die forging process design to ensure homogeneous grain size refinement of cast structures by three-dimensional rigid-plastic finite element analysis , 2004 .

[5]  Gary M. Bone,et al.  Real-Time Process Characterization of Open Die Forging for Adaptive Control , 2000, Manufacturing Engineering.

[6]  Young Hoon Moon,et al.  Pass schedule algorithms for hot open die forging , 2002 .

[7]  Wisama Khalil,et al.  A new geometric notation for open and closed-loop robots , 1986, Proceedings. 1986 IEEE International Conference on Robotics and Automation.

[8]  Reiner Kopp,et al.  Some current development trends in metal-forming technology , 1996 .

[9]  Patrick Martin,et al.  A contribution to technological data estimation for concurrent engineering using geometrical control of net shape forming parts , 2003 .

[10]  Alan N Bramley,et al.  Analysis for the automation of small batch manufacturing using open die forging , 1993 .

[11]  Y H Kim,et al.  An analysis of plastic deformation processes for twist-assisted upset forging of cylindrical billets , 2001 .

[12]  Jong-Rae Cho,et al.  Analysis of the cogging process for heavy ingots by finite element method and physical modelling method , 1998 .

[13]  F. H. Osman,et al.  Determination of experimental axial and sideways metal flow in open die forging , 2008 .

[14]  Young Hoon Moon,et al.  Optimization of open die forging of round shapes using FEM analysis , 2006 .

[15]  E. Appleton,et al.  Open die forging with industrial robots , 1979 .

[16]  Seung-Han Yang,et al.  Three-dimensional rigid-plastic FEM simulation of metal forming processes , 2006 .

[17]  Bunyamin Aksakal.  Analysis on a flexible forging cell , 2003 .

[18]  K. W. Lilly,et al.  Dynamic simulation and neural network compliance control of an intelligent forging center , 1996, J. Intell. Robotic Syst..