Holistic process planning chain for robot machining

Today, machining of large, integral constructed structural parts requires expensive machining centers. In contrast, modern industrial robots are suitable for a wide field of applications and are characterized large working
spaces and low capital investment. Therefore, they provide high economical potential for machining applications in aerospace industry, especially for the machining of near to shape pre-products like extruded profiles. However, their constructive characteristics like low stiffness and high sensitivity to vibrations lead to disadvantages compared with conventional machining centers and have to be considered during process planning. Therefore, several methods for offline and online optimization of robot machining processes were developed and integrated in a new process chain for manufacturing of structural fuselage parts. Thereby, the conventional CAD–CAM process planning chain was Extended with simulation based analysis and optimization methods and a load-depending trajectory planning. These methods for offline process optimization within this novel process chain are presented in this paper.