Industrial robots are characterized by good flexibility and a large working space, and offer a new approach for the machining of large and complex parts with small machining allowances (extra material allowed for subsequent machining). Parts of this type (such as aircraft skin parts, wind turbine blades, etc.) are easily deformed due to their large scale and low stiffness. Therefore, these parts cannot be directly machined according to the designed model. A feasible method is to plan a robotic machining path by using the point clouds of parts after clamping from onsite measurement which contains inherent defects of measurement such as noise points and abrupt points. In this article, a novel method is proposed to plan and optimize a robotic machining path that meets the requirements of smoothness, dexterity, and stiffness based on the point cloud from onsite measurement. The dual nonuniform rational B-spline curves of the machining path points and tool axis points are generated at first. Next, an objective function of smoothness optimization is established to filter out the local mutation of the path by considering the constraints of both the deformation energy and the deviation. Then, the objective function of robot postures optimization is established to optimize dexterity and Cartesian stiffness of a robot during the machining process. To show the feasibility of the proposed method, simulation and experiments are carried out. It is proved that the proposed method can generate a smooth machining trajectory. The stability of joint rotation and the rigidity and dexterity of the robot are improved during the machining process.

Multirobot systems have shown great potential in dealing with complicated tasks that are impossible for a single robot to achieve. One essential problem encountered in cooperatively working of the multirobot systems is the unknown initial transformation relationships from hand to eye, base to base, and flange to tool. In this article, the problem of multicoordinates calibration for a dual-robot system is formulated to a matrix equation AXB = YCZ. A novel approach for simultaneously solving the unknowns in equation AXB = YCZ is proposed, which is composed of a closed form method based on the Kronecker product and an iterative method which converts the calculation of a nonlinear problem to an optimization problem of a strictly convex function. The closed form method is used to quickly obtain an initial estimation for the iterative method to improve the efficiency and accuracy of iteration. In addition, a series of conditions on the solvability of the problem are proposed to guide the operators to select appropriate robot attitudes during the calibration process. To show the feasibility and superiority of the proposed iterative method, two other calibration methods are chosen to be compared to the proposed method through simulation and practical experiments. The comparison results verify the superiority of the proposed method in accuracy, efficiency, and stability.

The cutting force is one of the key factors for planning and optimizing the machining operation in material removal processes. An analytical cutting force prediction model that takes into consideration both edge effects and size effects based on the oblique cutting theory is developed and analyzed in this study. A detailed analysis of the cutting geometry is presented based on the coordinate system transformation and uncut chip thickness (UCT), which is evaluated on the rake plane instead of the reference plane. Then, the developed Johnson–Cook constitutive model of the workpiece that takes into consideration the size effects is then applied to the prediction of edge forces coefficients and cutting forces coefficients. The edge forces are predicted using the edge coefficients prediction model with the regularity found in the orthogonal simulations, which reflect the influences of chamfered length and chamfered angle. The developed model is validated using the turning operations of super alloys with round chamfered inserts. Finally, the effects of the cutter edge, cutting parameters, and UCT on the cutting forces are investigated using the developed model. The reasonableness and effectiveness of the proposed model is demonstrated through the comparison of the measured and predicted cutting forces for various chamfer characteristics.