Optimal Joint Path Planning of a New Virtual-Linkage-Based Redundant Finishing Stage for Additive-Finishing Integrated Manufacturing

This paper describes the optimal path planning of a redundant finishing mechanism developed for joint space-based additive-finishing integrated manufacturing (AFM). The research motivation results from an inevitable one-sided layout of a finishing stage (FS) with regard to the additive stage (AS) in the AFM. These two stages share a 2-dof bed stage (BS), and the FS can lightly shave off the rough-surfaced 3D print on the bed. Since the FS located at the side of the AS cannot reach all the target points of the 3D print, the bed should be able to rotate the 3D print about the z -axis and translate it in the z -axis. As a result, the AS has 4-dof joints for 2P and 1P1R during the additive process with AS-BS, and FS has 4-dof and 2-dof integrated joints for 2P2R and 1P1R during the finishing process with FS-BS, respectively. For the kinematic modeling of the FS part and the BS, the virtual linkage connecting the bed frame origin and the FS’s joint frame for approaching the BS is considered to realize seamless kinematic redundancy. The minimum Euclidian norm of the joint velocity space is the objective function to find the optimal joint space solution for a given tool path. To confirm the feasibility of the developed joint path planning algorithm in the proposed FS-BS mechanism, layer-by-layer slicing of a given 3D print’s CAD model and tool path generation were performed. Then, the numerical simulations of the optimal joint path planning for some primitive 3D print geometries were conducted. As a result, we confirmed that the maximum and mean pose error in point-by-point only, with the developed optimal joint path planning algorithm, were less than 202 nm and 153 nm, respectively. Since precision and general machining accuracies in tool path generation are in the range of ±10 μm and 20 μm, the pose error in this study fully satisfies the industry requirements.