Mechatronic coupling design proposal for integrating milling and drilling tools on the KUKA KR 16 robot

The manufacturing of components with complex geometries necessitates the adoption of advanced technologies, as conventional methods often fall short in achieving such intricate shapes. In this context, robotic machining has emerged as a leading alternative due to its flexibility, adaptability, and precision. This study presents the mechatronic design of a tool coupling system for milling and drilling applications using the KUKA KR 16 robot. The proposed design compares two coupling configurations: one mounted perpendicularly to the robot's flange, and the other inclined at 45 degrees. The evaluation includes an analysis of cutting forces during the machining of expanded polystyrene (EPS), along with the corresponding bending moments and structural deformations. Additionally, a kinematic analysis of various machining processes is conducted to assess the standard deviation and angular variation range of the robot's joints during operation. The results demonstrate that the deformations and bending moments experienced by both couplings do not compromise the structural integrity of the robotic system. Furthermore, the analysis indicates that the perpendicular coupling offers superior performance for horizontal surface machining, while the 45-degree inclined design is better suited for inclined surface operations.