Optimization of Modular Fixture Layout by Minimizing Work-piece Deformation
Abstract
The fixtures are utilized to locate and restrain a workpiece while different machining processes are performed on it. The workpiece must be properly located and clamped so that it could be manufactured according to the prescribed dimensions and tolerance. The actual purpose of fixture design is to maximize locating accuracy and workpiece firmness while minimizing deformations. The purpose of this work is to conduct a multi-objective optimization in order to minimize workpiece deflections due to clamping forces and optimized fixture layout by taking into consideration the boundary conditions and loads applied during a machining process. The locators are employed in a 3-2-1 fixture configuration. Then the empirical relations are used to calculate the machining forces and moments generated during drilling and milling processes and after that the workpiece is loaded to model those cutting forces. ANSYS parametric design language (APDL) code which made use of sub-approximation method is utilized to automatically optimize locator and clamp positions. Afterwards the clamping forces are being optimized using balancing force-moment method. Lastly, the maximum deformation of the workpiece against the optimum clamping forces is determined by harmonic analysis.
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