A novel force feedback model for virtual robot teaching of belt lapping

Virtual offline robot teaching provides a flexible and more economic robot programming solution to belt lapping. Due to the elasticity of the components, the applied force directly influences the polishing result, and the corresponding reaction force sensed by the user affects his or her decision on next operation. However, most of the simulation works reported so far focus mainly on the machining effect of belt lapping but not the contacting force. Therefore, this paper proposes a novel force feedback model for virtual robot teaching of belt lapping. By analyzing the force conditions at different process stages, three kinds of forces, namely natural force, colliding force, and resistance force, are defined to facilitate users with continuous force feedback during a virtual lapping process. To validate the model, a comparative study is done between the actual force measured during the belt lapping process and that simulated by the proposed force model. Moreover, evaluators are involved to conduct the virtual lapping of a mechanical part using the prototype developed. Both the quantitative and the evaluation experiments have validated that the force model is able to provide users with realistic force feedback and better ergonomic feelings of immersion. Moreover, they are also positive on the flexibility and efficiency of using the prototype for virtual robot teaching of belt lapping processes.