Performance Analysis of Cobalt Chromium Alloy Based Femoral Knee Components Polishing Using Industrial IRB 2400 Robot

The research aims to study the surface characteristics analysis of cobalt‐chromium alloy which is mostly used in femoral knee components using Industrial IRB 2400 Robot. Initially manual polishing from basic SiC abrasive papers to diamond slurry with a cloth polishing to achieve N2 grade of super finishing surfaces by the 11‐step process. For incorporating the observation to polish the curved surface workpiece, the curve fit method is used by projecting its surface's curves on 2D planes, and thus, data on several control points for each continuous curve is obtained which gives a uniform polishing. To obtain desired grade of polishing in the least robot cycle time, 3 M Trizact belts of P1200 and P2500 equivalent grades as used for 1st two polishing stations of the Robot Finishing Cell. An industrial robot manipulator IRB2400 is used for polishing the workpiece to N2 grade. Forward kinematics helps in deciding the best use of the robot's work cell and inverse kinematics is calculated for avoiding singularities. After incorporating the data of several control points into the Depth First Search algorithm of robot programming. Surface finish results are explained using experimental observations which address the achievement of N2 super‐finishing of the femoral knee component surfaces.