Value-addition of haptics in operator training for complex machining tasks

This paper presents a haptic simulator based on a force model that renders precise and crisp force feed back for a range of applications such as grinding, polishing and deburring of metals using an abrasive hand-grinding tool. Many skill based manufacturing and medical applications require a human operator to use grinding tools to impart force to remove material from a surface that may have rough texture or asperities. This paper describes the design, implementation and evaluation of this proposed system. First a force model is presented to compute forces resulting from grinding tool work piece interface. Next an image based 3D Terrain modeling algorithm is developed to simulate the details of work piece topology. To create sensation of metal removal during the grinding processes, a dynamic texture modification algorithm is developed to provide realistic virtual simulation of polishing process. Finally human subject tests are carried out to test the effectiveness of the simulator. The skill sets required for grinding operations are usually learned through practice. The grinding simulator presented here is a step towards using haptics to perfect this skill that is otherwise hard to learn quickly.