Contact Zone Force Profile and Machining Performance of Filamentary Brush1
Author:
Stango R. J.1, Cariapa V.1, Zuzanski M.1
Affiliation:
1. Department of Mechanical and Industrial Engineering, Marquette University, Milwaukee, WI 53233
Abstract
Filamentary brushing tools are used in a wide range of surface finishing processes, such as deburring, edge radiusing, polishing, and surface decontamination applications. Moreover, these tools are easily adapted to automation because the filament tips, which perform the machining operation, readily conform to the workpart surface without the need for sophisticated control systems technology. However, little is known about the material removal mechanics of filamentary brushes and, therefore, trial-and-error experimentation is often necessary before the tool is implemented in a production environment. This uncertainty of performance can be traced to a lack of understanding of the actual forces that are generated within the contact zone, that is, along the interface of the filament tip and workpart surface. Although previous experimental research has focused on the overall (i.e., resultant) brush force exerted onto the workpart, no information exists in the literature regarding the variation of force within the contact zone. Such information is essential for understanding the material removal profile within the contact zone, and could provide valuable information regarding the most active machining site along the contact surface. In this paper, a novel experiment is proposed for evaluating the force profile of filament tip forces that are generated within the contact region of a brushed surface. A specially designed workpart fixture is constructed and used in conjunction with a multiaxis force sensor for measuring the detailed force variation within the contact zone. The experiment is conducted using a wire brush at several different rotational speeds, which enables one to ascertain the role of filament inertia in the material removal process. Findings are reported which suggest that a significantly enhanced material removal rate can be achieved at a selective location within the contact zone at moderately elevated spindle speeds.
Publisher
ASME International
Subject
Industrial and Manufacturing Engineering,Computer Science Applications,Mechanical Engineering,Control and Systems Engineering
Reference13 articles.
1. FitzPatrick, P. R., and Paul, F. W., 1987, “Robotic Finishing Using Brushes—Material Removal Mechanics,” SME, Deburring and Surface Conditioning Conference, Phoenix, AZ, MR87-156. 2. Stango, R. J., Cariapa, V., Prasad, A., and Liang, S. K., 1991, “Measurement and Analysis of Brushing Tool Performance Characteristics—Part I: Stiffness Response,” ASME J. Eng. Ind., 113(3), pp. 283–289. 3. Cariapa, V., Stango, R. J., Liang, S. K., and Prasad, A., 1991, “Measurement and Analysis of Brushing Tool Performance Characteristics—Part II: Contact Zone Geometry,” ASME J. Eng. Ind., 113(3), pp. 290–296. 4. Stango, R. J., Heinrich, S. M., and Shia, C. Y., 1989, “Analysis of Constrained Filament Deformation and Stiffness Properties of Brushes,” ASME J. Eng. Ind., 111(3), pp. 238–243. 5. Shia, C. Y., and Stango, R. J., 1994, “On the Frictional Response of Circular Filamentary Brush in Contact With Planar Workpart,” Int. J. Mach. Tools Manuf., 34(4), pp. 573–589.
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