Comparative Study of Surface Quality on Flat and Curved UHMWPE Surfaces Using Robotic Milling

Shukri Zakaria; Wan Nor Shela Ezwane Wan Jusoh; Mahamad Hisyam Mahamad Basri; Mohamad Irwan Yahaya; Md Razak Daud

doi:10.24191/jaeds.v5i2.139

Authors

Shukri Zakaria Faculty of Mechanical Engineering, Universiti Teknologi MARA Penang Branch, Permatang Pauh Campus, Permatang Pauh, Penang
Wan Nor Shela Ezwane Wan Jusoh Faculty of Mechanical Engineering, Universiti Teknologi MARA Penang Branch, Permatang Pauh Campus, Permatang Pauh, Penang
Mahamad Hisyam Mahamad Basri Faculty of Mechanical Engineering, Universiti Teknologi MARA Penang Branch, Permatang Pauh Campus, Permatang Pauh, Penang
Mohamad Irwan Yahaya Faculty of Mechanical Engineering, Universiti Teknologi MARA Penang Branch, Permatang Pauh Campus, Permatang Pauh, Penang
Md Razak Daud Department of Mechanical Engineering, Politeknik Ibrahim Sultan, KM10 Jalan Kong Kong, Pasir Gudang, Johor Darul Takzim.

DOI:

https://doi.org/10.24191/jaeds.v5i2.139

Keywords:

Surface Geometry, Surface Roughness, Robotic Milling, UHMWPE

Abstract

In the context of robotic machining for advanced thermoplastics, surface geometry plays a critical role in determining surface quality.This study investigates the effect of surface geometry on the surface quality of ultra-high molecular weight polyethylene (UHMWPE) during robotic milling. Flat and curved geometries were machined using a 6-axis KUKA KR 120 R2700-2 F at spindle speeds of 6500 and 9500 RPM. Surface roughness parameters (Ra, Rq, Rz) were evaluated through a Mitutoyo SJ-410 stylus profilometer to assess the resulting surface quality. The results show that increasing spindle speed improved surface finish across both geometries. Curved surfaces consistently achieved lower roughness values compared to flat surfaces, with Ra improved by 27.5% (from 1.669 µm to 1.209 µm) and Rz by 33.1% (from 8.778 µm to 5.877 µm) on curved geometries. Conversely, flat surfaces experienced higher roughness but Ra still showed improvement by 29% (from 2.331 µm to 1.656 µm) and Rz by 36.2% (from 11.765 µm to 7.509 µm) with increased spindle speed. Despite fluctuations, all roughness values remained acceptable for industrial use, particularly in sliding components, structural spacers, and food-grade parts. The findings emphasize the importance of considering surface geometry in tool path planning and thermal compensation strategies for high-precision robotic milling of UHMWPE.

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