The article concerns the possibility of the automation and robotization of the process of deburring jet engine components. The paper presents the construction of a laboratory stand enabling the automation of selected production operations of typical low-pressure turbine blades. The work identifies important parameters and results of the technological process related to the removal of burrs that affect the exactness of the process. The results of the analysis of the impact of individual process parameters on the magnitude of forces and moments occurring during deburring were carried out and presented. The results of initial and detailed tests were presented. Based on the results obtained, it was noticed that doubling the rotational speed of the brush results in a linear increase in torque and an increase in the engagement of the detail in the disc brush, leading to a non-linear increase in torque. It has also been shown that with tool wear, the value of the torque generated by the rotating tool decreases. Based on the results of a comparison of manual and automated process and histogram analysis, results from an automated stand are centered more correctly inside of the required radius range. This means that the repeatability of the process is higher for an automated test stand, which is one of the key aspects of large-scale aviation component manufacturing. Additionally, it was confirmed by visual inspection that all burs had been removed correctly—the deburring operation for all tested work pieces was successful. Based on the results obtained, it was proven that introduction of an automated stand can improve working conditions (by the elimination of the progressive fatigue of employees and the possibility for injury) and allows for the elimination of the negative impact of the machining process on workers. Further areas in which the optimization of the process parameters of the edge deburring can be developed in order to reduce unit costs have also been indicated.

This paper presents a method of numerical simulation, using the finite element method for the brush wear process during the deburring of the edge of the workpiece. The work was carried out in the Ansys Workbench environment in the Ansys Mechanical module. This study reviews the effect of selected parameters of the technological process (rotational speed and depth of tool penetration into the workpiece) on the abrasive wear of the tool. The discussion examines the subject of the 3D or 2D approach in terms of results, quality, and time of computation. A series of numerical analyses (2D) were carried out to investigate the effect of process parameters on the wear rate and, consequently, on the tool life. Obtained results on the quantity of worn material were critically assessed in relation to real-world industrial conditions. The difference between the numerical model and the test performed in the industry environment varied from 3 to 46% and was discussed in this paper. Additionally, to improve the quality of the results in Ansys, an APDL script with adaptative mesh was prepared. The article contains a discussion on the possibility of numerical model development.

This article presents a procedure for preparing the geometric foundation of a digital twin of a robotic station planned for an existing production hall. The procedure combines environmental mapping using an Apple iPad Pro 13 equipped with LiDAR and the RobotStudio® AR Viewer application with the proposed use of a Leica AT960 tracker for reference measurements. The scan was saved in RSSCAN format, processed in RobotStudio and ATOS Professional, and integrated with the CAD design of the station. Of the six scans acquired, scans 5 and 6 were selected for a local comparison. Following rigid registration, the mean distance at ten points along a wall cross-section was 15.6 mm, the root mean square (RMS) distance was 19.3 mm, and the maximum was 39.1 mm. Following floor-prioritized registration, the corresponding values for ten points along a selected segment were 2.9 mm, 3.7 mm, and 8.4 mm. These results describe differences between the scans rather than accuracy relative to the hall; they also do not constitute a direct comparison of the two registration variants. A coordinate transformation model and an independent validation procedure were developed. The resulting scene supports a preliminary assessment of the station layout, whereas its use for robot programming requires reference measurements and validation after installation.

This study presents a preliminary geometric modeling workflow for a robotic station planned for an existing production hall. An iPad Pro 13 with LiDAR and RobotStudio AR Viewer captured the surroundings; RobotStudio and ATOS Professional supported data exchange, local scan comparison, and placement of the station CAD model. Six scans were acquired. Scans 1–4 covered restricted passages because stored product boxes obstructed the area; scans 5 and 6 provided broader coverage. At ten selected points, the wall comparison yielded a mean distance of 15.6 mm, a root mean square (RMS) of 19.3 mm, and a maximum of 39.1 mm. A separate floor-prioritized comparison yielded 2.9, 3.7, and 8.4 mm, respectively; these cases do not constitute a controlled comparison of registration methods. Six Leica AT960 point measurements and corresponding scan 6 coordinates were additionally examined using point 4 as the origin. For the five non-origin points, the three-dimensional coordinate discrepancy RMS was 48.62 mm and the maximum was 61.80 mm. The contribution is an application workflow with explicit separation of local inter-scan agreement, reference-coordinate comparison, and future validation. The model supports preliminary layout visualization; a functioning digital twin, verified clearances, and collision-free robot operation remain outside the demonstrated scope.

The article concerns the possibility of carrying out an optimization process of the extending the life of a brush tool which is use during the process of removing burrs and rounding edges. The work focused on the influence of selected parameters on the wear time of tools. A number of tests were carried out to optimize the selection of parameters in terms of tool life, while maintaining the proper quality of the manufactured products, which translates into their reliability. As part of the work carried out, an optimal set of parameters was prepared to extend the tool's operational time. These parameters are the rotational speed of 1400 rpm and the external diameter of the tool of 200 mm. Thanks to the use of new parameters of the brushing process, the tool's operational time was extended by about 67%. The work carried out, after verification as part of large-scale production, led to a reduction in the consumption of tools, which had a positive impact on the improvement of the company's financial result (reduction of cost per part) and also contributed to the reduction of the carbon footprint. The work indicates further areas for development.