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Current and Potential Robotic Abrasive Waterjet Systems by Mohamed Hashish, Ph.D., Flow International Corporation, Kent, Washington, USA

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Current and Potential Robotic Abrasive Waterjet Systems by Mohamed Hashish, Ph.D., Flow International Corporation, Kent, Washington, USA Current and Potential Robotic Abrasive Waterjet Systems By Mohamed Hashish, Ph.D., Flow International Corporation, Kent, Washington, USA 2013 WJTA-IMCA Conference and Expo September 9-11, 2013 George R. Brown Convention Center Houston, Texas See pages 18-22 for details Abrasive Water Jet (AWJ) Cutting Head. On the inside Meet the Candidates for the WJTA-IMCA Board of Directors ...........................................................pg. 4 NLB Surface Prep Equipment Helps BNY Mellon Center Earn Project of the Year Award ....pg. 10 Jetting Away the Impurities ...............................................pg. 10 Michael Waltrip Racing, Jet Edge Renew Large Gantry for Boeing 787 Technical Partnership ....................................................pg. 12 Wing Trimming. Courtesy MHI. Typhoon™ Rotating Nozzles Clean Small Pipes .............pg. 12 Contractor Develops Clamp to Improve See article on page 2. Vacuum Truck Grounding Issue ....................................pg. 14 Current and Potential Robotic Abrasive Waterjet Systems By Mohamed Hashish, Ph.D., Flow International Corporation, Kent, Washington, USA ABSTRACT 5-axis gantry robots and 6-axis ar- ticulated arm robots have been used with plain waterjets for many appli- cations, especially in the automotive industry. This paper is on extending the use of these robots to abrasive waterjets and for a much wider range of applications. The integration of the abrasive waterjet process on robotic Figure 1: Gantry Structural Analysis Using Finite Element Analysis arms has been successfully developed to address the end effector, supply tions, the robot accuracy and repeat- because they are the most used in of high pressure water and abrasives ability have been sufficient. multi-axis waterjet cutting. to the cutting head, and operational safety. Off line programming, cali- For accurate processing of workpieces, 2.1 5-Axis Gantries bration and inspection are discussed. especially cutting with a beam-like Advanced software packages typically cutting tool such as waterjet or abra- The 5-axis gantry systems represented used in the aerospace industry have sive waterjet (AWJ), more understand- by Figure 1 are Cartesian manipulators been successfully adapted. The need ing of all aspects and process variables and are designed with a relatively high for enhanced accuracy performance that affect accuracy is necessary. degree of structural stiffness in order using first article inspection results is These variables can stack up and result to achieve the required accuracy. It is discussed. A few case studies are pre- in out-of-tolerance parts. These vari- typical in the design of these systems sented in this paper addressing com- ables could be related to the manipu- to study their structural, kinematic posite trimming for wing skins used lator, fixture, material, tool/process and dynamic behaviors using analysis in aircraft and wind turbines and for and the environment. The robot, for software packages such as finite stone cutting with hybrid processes. It example, is a complex assembly of elements. For example, Figure 1 was found that 6-axis robot arms can interconnected links, gears, gear trains, (right) shows the results of a finite easily be implemented when moderate servo drives, harmonic drives and element analysis used to determine accuracies, from 0.010 inch (0.25 mm) even belt drives. These result in po- the deflection of a gantry bridge under to 0.015 inch (0.38 mm) are specified. sitional and path errors which need to given loads. The analysis may also However, accurate calibration and first be compensated for. Also, recognizing include thermal deformation and article inspection procedures were the idiosyncrasies of the material such whether environmental control will be found necessary to obtain accuracies as homogeneity, shrinkage, warping, required or not based on the required below 0.01 inch (0.25 mm). Much etc. will lead to minimized errors by part accuracy. The deflection data can tighter accuracies are achieved with proper compensation (1-3). be used for compensation in order to stiff gantry systems. obtain more accurate results. In this paper, we first address manipu- lators for waterjet applications, cover- These gantry units are sometimes 1. INTRODUCTION ing gantry and 6-axis robots. Then, installed on a machine tool founda- we will address AWJ applications such tion and housed in a controlled en- Today, thousands of multi-axis robotic as trimming, cutting and shaping using vironment to maximize stiffness and cells are deployed worldwide in a 6-axis robots with focus on composite minimize the thermal effects. When variety of high production environ- trimming. Conclusions are listed at mechanical end effectors such as rout- ments. These include manufacturing the end of the paper. ers are integrated into waterjet gantry of standard and customized compo- systems, the stiffness requirement be- nents, prototype designs, and low and 2. MANIPULATORS comes the driving factor for machine high volume mass production of large construction. and medium batch sizes for OEM and aftermarket sectors. In these applica- In this section we address 5-axis gantry robots and 6-axis robotic arms (continued on page 14) Page 2 WJTA-IMCA - www.wjta.org May 2013 Meet the Candidates for the WJTA-IMCA Board of Directors JOOST BALLIEUX is the general discussions and collaborations, as well as help to grow the manager for Peinemann Equipment membership so that the association becomes a strong voice B.V., Hoogvliet, Netherlands. for small and large corporations within the industry. He holds a degree in commercial economics and studied civil Nominated by: Mohan Vijay, Ph.D., President, VLN engineering. Following a tour of Advanced Technologies, Inc., Ottawa, Ontario, Canada. duty in the army on a mission with the United Nations to Bosnia as a communications specialist, Mr. FRED CLARK is the CEO and Ballieux worked for a trading company in the Middle corporate secretary for IVS Hydro, East to implement ISO 9000 and later joined the sales Inc. As the only remaining original force where he was introduced to Peinemann. He joined stockholder in the company, which Peinemann in 1998 as a sales manager and later became was founded in 1972 by his father, the company’s general manager. himself, and two other co-founders, he has dedicated over 40 years to Mission/Vision: In the last 15 years, I have personally the growth of the company in the dedicated most of my time to find solutions for high areas of waterblasting and vacuum pressure cleaning jobs, mainly for cleaning heat truck services. Being a 1976 graduate of the West Virginia exchangers, with the help of a few local Dutch cleaning University School of Law and a practicing attorney could contractors and other people from the field of high pressure not even keep him away from the business created in his cleaning. As we do business on a worldwide level, it is my own back yard. From performing work as a waterblaster goal to promote hands free cleaning in every country of himself during the 1970s to working his way through the the world to avoid (deadly) high pressure accidents that business overseeing operations, accounts, accounts payable still take place very year. I believe I could bring a bit of and receivable, safety, and eventually becoming CEO in European know-how and mentality to the WJTA-IMCA 2000, Mr. Clark has first-hand knowledge of the industry, Board to make the organization more international and its practices, its growth, and most importantly, its potential. help to make the organization grow on a global level. IVS Hydro, Inc. will celebrate its 41st anniversary in June 2013 and has become a national multi-division/ Nominated by: Kerry Petranek Siggins, Chief Executive multi-million dollar corporation within the industry. With Officer, StoneAge, Inc., Durango, Colorado. divisions in industrial services, hydrodemolition services, environmental services, silo and bulk storage services, dredge and dewatering services, and most recently adding WILLIAM BLOOM has been commercial diving services, Mr. Clark remains committed the vice president of business to the advancement of waterblasting and this industry development at VLN Advanced throughout the 21st century. Technologies, Inc., in Ottawa, Ontario, Canada, since 2000. His expertise has Mission/Vision: I wish to see the continued growth of our been utilized in the commercialization industry and expansion into broader areas of industrial, of the Ultrasonic Forced Pulsed Water manufacturing, utilities, and mainstream government Jet. Mr. Bloom’s communications work. Allowing our industry to grow with the advancement skills and ability to build relationships of technology yet still maintaining the basic core values of in industry have helped to produce opportunities in the safety in waterblasting is a key component to the growth aerospace, automotive, nuclear, and other industries. and recognition of the WJTA-IMCA as a national and international leader in safety, best practices, and product Mission/Vision: As a member of the WJTA-IMCA and development. I believe the continued involvement and having attended conferences over the past 13 years, coexistence of contractors, manufacturers of industry I believe my mission and vision for the WJTA-IMCA is products, vendors who provide the necessary accessories to build awareness of the safety practices within industry, be a steward within the industry for the environment, engaging the membership in meaningful educational (continued on page 5) Page 4
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