Flexible Robotic Machining Solutions you should Beware of


Using industrial machining robotics is one of the ideal ways of reducing energy costs in manufacturing facilities. Machining robots are not only adaptable and flexible but can also be used for multiple purposes. Read on to understand the various machining robotic solutions available today. 

History of Robotics

Robotics is among the most popular technologies in the world. Demand for robotic automation has been rising rapidly in recent years. The evolution of computer numerical control (CNC) machining processes such as turning, grinding, and milling began back in the 1970s. 

Industrial robots for welding and handling applications also became popular around this time. CNC technology faces various limitations like motion complexity, scalability, flexibility, and cost challenges. As a manufacturer, you can easily overcome these issues with machining robotics. The combination of CNC machining and robotic machining started at the beginning of the 2000s. 

Machining robotics is a broad spectrum that includes sculpting and milling, robotic de-flashing of forgings and castings and grinding, robotic cutting and trimming, robotic de-burring and robotic polishing and finishing. These systems comprise a controller and an industrial robot, tool rack, tool changers, spindles, programming software, and fixtures. 

Machining robotics is a vital transition to Industry 4.0 from Industry 2.0. It also forms a basis for the next manufacturing generation. This shift to smart manufacturing processes will highly influence the consistent and improved quality, productivity, reduction of cycle time, multitasking and flexibility, safety and health, and promote a neat and safe working area. 

Machining Robotic Approaches 

Robotics feature key technologies like process or application development, fixtures and tooling, and programming and controls software. There are two machining robotic approaches, as seen below. 

Moving Robotic Tools 

In this approach, multiple or one tool is fixed on a robot arm while the workpiece is fastened at the fixture. This approach is ideal for a wide range of large parts.  

Moving Robotic Parts 

In this case, multiple or one tool is mounted in a cell while a gripper and robot move the workpiece. This approach is ideal for small objects manufactured in dedicated production facilities.  

Quality of Automated Robotic Delivery 

Machining robotics involves the utilization of industrial robots to standardize and automate repeatable manufacturing tasks and procedures. In this process, automation comes with numerous benefits to producers of castings, like improved product quality and productivity. It also guarantees a safe and healthy working environment. 

The idea behind robotic fettling technology and how it can be deployed successfully in the iron casting sector acts as a dos and don’ts guide for proper executions. Assembled parts iron castings come with sophisticated shapes. In this case, you may want to use automated robots to facilitate precise and quality products. 

Robotic Fettling Systems

Robotic fettling and grinding enhances completeness and flexibility. Manual operations involve many variations round the clock where operators work in different styles. Different operators handle one component, which may trigger handling damages. When operators cut tools manually, they may cause dents, scratch marks, or cutting into undesirable areas. 

The tool selection feature in grinding robotics is crucial because the system’s running cost, process reliability, and running costs are based on its tool. Often, choosing the right tool can reduce running costs and cycle time by up to 90%. The popularly used tools in fettling robotics are diamond-coated wheels for grinding and cutting. 

Various costs are associated with robotic fettling, and you should consider them when calculating the cost for each piece. These costs include energy, maintenance, reprogramming, retooling, labor, and consumable costs. 

When calculating the return on investment of your fettling robotic system, you want to consider consistent improvement. Reducing the need for reworking and rejection rate helps you make major savings. Proper application choice and implementation can guarantee a return on investment from your fettling robotic system within two years.  


Tool selection is a critical part of machining robotic technology. You have to understand various parameters like the flash level, process, material removal, material, running cost, predicted cycle time, and reliability. This knowledge will help you make choose the ideal robot for your applications.