Method to off-line program robotized metal deposition

Abstract: This report is a ten credit degree project and is aimed at technically skilful personnel at Volvo Aero Corporation and at the University West. The goal of the project is to create a robot program that can manufacture a part by Metal Deposition from a 3-D CAD model (Unigraphics) via a CAM module and a CAR program (IGRIP) to an ABB robot. Metal Deposition is a method to build new parts, add material to an existing part and repair components that have been damaged in earlier processes. The method can be used with different kinds of welding with powder or welding wire as the additive material. Three reference geometries were used; two bosses and a circular sweep. UG/CAM is used to create the CLS (Cutter Location Source) data. Different milling operations are used to emulate welding.The program which imports the coordinates from the CLS data to IGRIP, as well as the export program, was written in GSL (Graphics Simulation Language). GSL is a Pascal-like programming language used to control the behaviour of simulation models. The import program reads linear movement coordinates line by line until the whole CLS file has been converted into IGRIP. UG/CAM should only use linear movement when using this program. If circular movements are used, a feature that converts those has to be added to the import program.