Mesh Automation

Robotic Grinding of Cast Aluminum

Mesh Automation > Case Studies > Robotic Grinding of Cast Aluminum
Close-up view of a robotic grinding machine component inside an enclosure, showing various motors, wiring, and mechanical parts designed for precision grinding operations.
A robotic arm equipped with a grinding wheel inside an enclosed setup, ready for the automated grinding of cast aluminum parts. Various control and support components are visible within the enclosure.
Exterior view of a MESH Automation robotic grinding machine enclosure in an industrial setting, showcasing a robotic arm designed for grinding cast aluminum parts. The enclosure ensures safety and efficiency during operations.
Close-up view of a robotic grinding machine component inside an enclosure, showing various motors, wiring, and mechanical parts designed for precision grinding operations.
A robotic arm equipped with a grinding wheel inside an enclosed setup, ready for the automated grinding of cast aluminum parts. Various control and support components are visible within the enclosure.
Exterior view of a MESH Automation robotic grinding machine enclosure in an industrial setting, showcasing a robotic arm designed for grinding cast aluminum parts. The enclosure ensures safety and efficiency during operations.
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Customer Requirements

Our customer was interested in robotically grinding four different aluminum castings. These castings have perimeter parting lines, internal slots and holes and oversized gates that need to be removed prior to coating, the next step in the manufacturing process.

Currently, workers in personal protection gear manage the process, with each product being touched three or four times. This inefficient process includes parts presented randomly in foundry bins, manually removing the unwanted parting lines and excess gate materials using grinding belts and wheels. Production output was inconsistent, hard to predict and track, thus resulting in the temporary loss of parts.

The MESH Solution

Our MESH cell had a combination of steel walls, viewing windows, a base platform, and a steel top. This structure contained the dust and fines created in the process and aided in noise abatement. This solution provided consistent output, improved process management, including predictable throughput and high-quality parts. Additionally, by eliminating human interaction from this challenging environment, these individuals were able to use their talents to improve the overall efficiency of the plant.

Equipment Used
  • MiniMAC - A steel weldment platform with internal beam supports, leveling feet, forklift access features, and a solid top plate system. The robot, material removal powered tools, electrical controls, cable management and fine management system are located on the solid plate system.
  • FANUC M20iD-35- This 6-axis industrial robot manipulates the parts against the material removal media. A robust material handling utility dress package and a tool mount for the range of part grippers was also added to the plate.
  • MESH-designed main tool - A pneumatically-compensated backstand which is durable and controlled and can coordinate with the forces being applied by the robot to adjust the material removal rate.
  • Powered Reamer - Used to clear holes of varying sizes found in the parts.
  • Radially-Compliant Spindle - Used for clearing slots and small features in the parts. The reamer and the spindle use hardened steel tooling.
  • Two-Position Turntable - Ppresents the parts. Each part type has a 3D printed fixture plate and was machined for datum control and marked for tracking and storage purposes. The turntable is powered by an electric servo drive.
    • Once completed, the parts are dropped into a gravity chute and sent out of the cell into a waiting bin. The main disconnect, power panel, the PLC, robot controller and pneumatics are on the outside of the enclosure for access reasons.
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