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In customized production such as plate workpiece grinding, because of the diversity of the workpiece shapes and the positional/orientational clamping errors, great efforts are taken to repeatedly calibrate and program the robots. To change this situation, the purpose of this study is to propose a method of robotic direct grinding for unknown workpiece contour based on adaptive constant force control and human–robot collaboration.

First, an adaptive constant force controller based on stiffness estimation is proposed, which can distinguish the contact of the human hand and the unknown workpiece contour. Second, a normal vector search algorithm is developed to calculate the normal vector of the unknown workpiece contour in real-time. Finally, the force and position are controlled in the calculated normal and tangential directions to realize the direct grinding.

The method considers the disturbance of the tangential grinding force and the friction, so the robot can track and grind the workpiece contour simultaneously. The experiments prove that the method can ensure the force error and the normal vector calculating error within 0.3 N and 4°. This human–robot collaboration pattern improves the convenience of the grinding process.

The proposed method realizes constant force grinding of unknown workpiece contour in real-time and ensures the grinding consistency. In addition, combined with human–robot collaboration, the method saves the time spent in repeated calibration and programming.

Compared with other related research, this method has better accuracy and anti-disturbance capability of force control and normal vector calculation during the actual grinding process.

This study aims to investigate a systematic approach to the production and use of additively manufactured injection mould inserts in product development (PD) processes. For this purpose, an evaluation of the additive tooling design method (ATDM) is performed.

The evaluation of the ATDM is conducted within student workshops, where students develop products and validate them using AT-prototypes. The evaluation process includes the analysis of work results as well as the use of questionnaires and participant observation.

This study shows that the ATDM can be successfully used to assist in producing and using AT mould inserts to produce valid AT prototypes. As a reference for the implementation of AT in industrial PD, extracts from the work of the student project groups and suitable process parameters for prototype production are presented.

This paper presents the application and evaluation of a method to support AT in PD that has not yet been scientifically evaluated.

Three-dimensional (3D) printed parts usually have poor surface quality due to layer manufacturing’s “stair casing/stair-stepping”. So post-processing is typically needed to enhance its capabilities to be used in closed tolerance applications. This study aims to examine abrasive flow finishing for 3D printed polylactic acid (PLA) parts.

A new eco-friendly abrasive flow machining media (EFAFM) was developed, using paper pulp as a base material, waste vegetable oil as a liquid synthesizer and natural additives such as glycine to finish 3D printed parts. Characterization of the media was conducted through thermogravimetric analysis and Fourier transform infrared spectroscopy. PLA crescent prism parts were produced via fused deposition modelling (FDM) and finished using AFM, with experiments designed using central composite design (CCD). The impact of process parameters, including media viscosity, extrusion pressure, layer thickness and finishing time, on percentage improvement in surface roughness (%ΔRa) and material removal rate were analysed. Artificial neural network (ANN) and improved grey wolf optimizer (IGWO) were used for data modelling and optimization, respectively.

The abrasive media developed was effective for finishing FDM printed parts using AFM, with SEM images and 3D surface profile showing a significant improvement in surface topography. Optimal solutions were obtained using the ANN-IGWO approach. EFAFM was found to be a promising method for improving finishing quality on FDM 3D printed parts.

The present study is focused on finishing FDM printed crescent prism parts using AFM. Future research may be done on more complex shapes and could explore the impact of different materials, such as thermoplastics and composites for different applications. Also, implication of other techniques, such as chemical vapour smoothing, mechanical polishing may be explored.

In the biomedical field, the use of 3D printing has revolutionized the way in which medical devices, implants and prosthetics are designed and manufactured. The biodegradable and biocompatible properties of PLA make it an ideal material for use in biomedical applications, such as the fabrication of surgical guides, dental models and tissue engineering scaffolds. The ability to finish PLA 3D printed parts using AFM can improve their biocompatibility, making them more suitable for use in the human body. The improved surface quality of 3D printed parts can also facilitate their sterilization, which is critical in the biomedical field.

The use of eco-friendly abrasive flow finishing for 3D printed parts can have a positive impact on the environment by reducing waste and promoting sustainable manufacturing practices. Additionally, it can improve the quality and functionality of 3D printed products, leading to better performance and longer lifespans. This can have broader economic and societal benefits.

This AFM media constituents are paper pulp, waste vegetable oil, silicon carbide as abrasive and the mixture of “Aloe Barbadensis Mill” – “Cyamopsis Tetragonoloba” powder and glycine. This media was then used to finish 3D printed PLA crescent prism parts. The study also used an IGWO to optimize experimental data that had been modelled using an ANN.

With the increasing demands of industrial applications, it is imperative for robots to accomplish good contact-interaction with dynamic environments. Hence, the purpose of this research is to propose an adaptive fractional-order admittance control scheme to realize a robot–environment contact with high accuracy, small overshoot and fast response.

Fractional calculus is introduced to reconstruct the classical admittance model in this control scheme, which can more accurately describe the complex physical relationship between position and force in the interaction process of the robot–environment. In this control scheme, the pre-PID controller and fuzzy controller are adopted to improve the system force tracking performance in highly dynamic unknown environments, and the fuzzy controller is used to improve the trajectory, transient and steady-state response by adjusting the pre-PID integration gain online. Furthermore, the stability and robustness of this control algorithm are theoretically and experimentally demonstrated.

The excellent force tracking performance of the proposed control algorithm is verified by constructing highly dynamic unstructured environments through simulations and experiments. In simulations and experiments, the proposed control algorithm shows satisfactory force tracking performance with the advantages of fast response speed, little overshoot and strong robustness.

The control scheme is practical and simple in the actual industrial and medical scenarios, which requires accurate force control by the robot.

A new fractional-order admittance controller is proposed and verified by experiments in this research, which achieves excellent force tracking performance in dynamic unknown environments.