Robotic Grinding

Robotic Grinding Machine for Foundry Castings

ATD Engineering & Machine develops robotic grinding solutions for foundries looking to automate demanding casting-finishing operations, from automated grinding casting trials to repeatable production finishing. Utilizing a robot to grind castings is our niche in the automation world. As foundries struggle to find labor for manual grinding of castings, we have stepped in with robotics. Robotic grinding removes much of the danger to your operator, while also producing a finish grind that is repeatable and within spec. Our robotic grinding development cell combines industrial robotics, servo-driven grinding tools, and force control to support repeatable finishing results. Each application is evaluated around the casting, grinding requirements, and production process to determine the appropriate tooling, robot motion, and cell configuration.

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ATD Engineering & Machine Robotic Servomotor Grinding with Force Control

pRODUCT oVERVIEW

ATD operates a dedicated test and development cell for robotic grinding of foundry castings. We have invested heavily in this cell at our own facility, building it over the past 3 years. The cell combines an industrial robot with servo-driven grinding equipment to evaluate automated casting grinding processes.

Foundry Casting automated grinding with force control

The development cell includes:

  • 17 hp PushCorp Servo Belt Sander
  • 30 hp Custom Snag Grinder
  • 10 hp PushCorp Servo-Driven Spindle rated at 15,000 rpm
  • 180 kg Motoman Industrial Robot

Key Features of ATD Robotic Grinding Machine

  • Servo-Motor Grinding with Force Control: Combines servo-driven grinding equipment and force control to manage tool contact with the casting during grinding.
  • Part-to-Media Grinding: The robot moves the casting against a stationary grinding tool. ATD identifies this as the arrangement used in its current development cell and notes that it accounts for about 75% of how most grinding is done.
  • Media-to-Part Grinding: The grinding tool moves against a casting held in position. ATD also has experience with this arrangement when the application calls for it, depending on the casting and your application.
  • Offline Robot Simulation: ATD can conduct offline studies using FANUC, ABB, and Motoman programming software. Its MotoSim environment in the R&D cell can be used to study the proposed grinding process before grinding a single casting and before physical casting trials.

ATD Engineering & Machine evaluates robotic grinding for foundry castings based on the type of excess material, the areas requiring grinding, and the required surface finish.

Robotic Grinding Applications

Casting Flash and Excess Metal Removal

Evaluating snag grinding to remove excess metal along casting edges, parting lines, or other areas where material must be removed.

Grinding Casting Edges and Contours

Developing robot paths to follow accessible edges or contoured surfaces that require controlled material removal.

Grinding Accessible Casting Surfaces

Assessing a servo-driven belt sander for grinding surfaces that the abrasive belt can reach and contact effectively.

Burr Removal

Assessing whether robotic grinding can remove burrs formed during casting or subsequent operations, depending on their size, location, and the casting geometry.

Grinding Localized Areas

Evaluating a servo-driven spindle for grinding specific areas of a casting where a spindle-mounted abrasive tool can access the required surface.

Repeatable Grinding Operations

Programming a defined grinding path for recurring casting designs when part positioning and dimensional variation allow consistent tool contact.

Factors Evaluated for Robotic Grinding​

Casting Geometry

Identify the surfaces, edges, and contours that require grinding and assess tool access.

Part Positioning

Assess how the casting can be held and presented consistently during grinding.

Material Removal Requirements

Determine the amount and location of excess material that needs to be removed.

Finish Requirements

Define the required surface condition and determine whether the proposed grinding process can achieve it.

Tool Selection

Evaluate whether a belt sander, snag grinder, or servo-driven spindle is suitable for the required operation.

Ready to Discuss Your Robotic Grinding Project?

ATD Engineering & Machine can evaluate your casting and grinding requirements to determine whether a robotic solution is suitable for your operation. Our team can assess the part geometry, material-removal requirements, tool selection, and grinding arrangement, with offline simulation and development trials considered where appropriate. Contact ATD to discuss your robotic grinding and polishing project and the next steps for evaluating your application.

FREQUENTLY ASKED QUESTIONS

  • Robotic grinding uses an industrial robot to guide a grinding tool or present a casting to abrasive media. In foundry applications, it can automate defined finishing tasks that would otherwise require manual grinding.

  • Robotic grinding foundry applications can include snag grinding, belt grinding, spindle grinding, and other specified casting-finishing operations. The appropriate method depends on the casting geometry, material to be removed, and required finish.

  • In part-to-media grinding, the robot moves the casting against a grinding tool or abrasive media. In media-to-part grinding, the tool is moved toward the casting. The best arrangement depends on the part, tool access, and process requirements.

  • Force control helps regulate contact between the grinding tool and the casting. This is important when developing a process that must accommodate contact conditions while meeting the specified material-removal and finish requirements.

  • ATD has a grinding test and development cell for evaluating applications. The team can also perform offline robot studies using FANUC, ABB, and Motoman programming software to assess a proposed process before physical grinding trials.

  • ATD's published development cell includes a 17 hp servo belt sander by PushCorp, a 30 hp custom snag grinder, and a 10 hp, 15,000 rpm servo-driven spindle by PushCorp. The appropriate tool for a production application depends on the casting and finishing requirements.

  • Robotic grinding may be suitable for robotic deburring casting applications where burrs or excess material can be accessed and removed using a controlled tool path. Suitability must be evaluated against the casting geometry, burr characteristics, tooling, and required finish.