Optimization of Machining Fixture Layout

K.A.Sundararaman, Assistant Professor, Department of Mechanical Engineering,

SSM Institute of Engineering and Technology, Dindigul, Tamilnadu, India.
E-mail:arunsunder@rediffmail.com

1.0 Introduction

Higher efficiency and lower production costs in terms of product

quality and productivity - development of automated manufacturing
systems.

Fixture - locate and constrain the workpiece during machining,

inspection and assembly.

Design and manufacturing of fixtures become costlier because of

tight tolerance and restrictions in the machining operations.

Design and fabrication of fixtures incur 10-20 % of the total cost

spent in the manufacturing system.

1.0 Introduction (Contd.,)

Fixtures-To locate and constrain a workpiece during machining

operation, includes locators and clamps.

In machining fixture layout, externally applied clamping force and

reactions exhibited in locator causes moment which in turn produces
deformation on machined workpiece. The moment is influenced not only

by the magnitude of clamping forces and reactions but also by the

positions of fixture elements.

Clamping and cutting forces can not be minimized beyond a extent.

Hence, the interrelationship between the position of fixture elements and

workpiece deformation is critical to ensure the accuracy of the
machining process.

1.0 Introduction (Contd.,)

Conventionally, an appropriate position for fixture elements is determined
by relying on design experience or trial and error methods which are
proved to be expensive and time consuming.
No assurance of optimal or near optimal solutions. Further, these
practices are not flexible.
Numerical models like FEMs were used to replace the analytical models.

Many researchers have been used FEM for modeling and analysis fixture
workpiece interactions. Commercial finite element solver has also been
employed for FEM calculations. ANSYS software was used to calculate
the displacement of the workpiece at the time of machining.

1.0 Introduction (Contd.,)

Author

Year

Objective

Design criteria

Tools used

Menassa
and
DeVries

1991

To determine the
position of supports

The minimization of the

workpiece deflection at
selected points as the
design criterion

FEA

Meyer
and Liou

1997

To synthesize fixtures
for dynamic machining
conditions

For the minimum

clamping forces and
locator forces is given

Linear
programming
technique

Li and
Melkote

1999

To optimize layout
problem

Minimizes workpiece
location errors due to
localized elastic
deformation of the
workpiece.

Nonlinear
programming
method

Roy and
Liao

1999

To plan for the best

supporting and
clamping positions

Tao et al.

1999

Determining the optimal

clamping points and
clamping sequence

---

For arbitrarily shaped

workpieces

Heuristic
method
A geometrical
reasoning
methodology

1.0 Introduction (Contd.,)

Author

Year

Objective

Design criteria

Liao and
Hu

2000

Fixtureworkpiece
system subject to timevarying machining loads

Li and
Melkote

2001

Combined fixture layout

and clamping force
optimization

---

Contact elasticity
modeling method

Amaral et 2004
al.

Optimization analysis

---

ANSYS

Tan et al.

2004

Modeling, analysis and

verification of optimal
fixturing configurations

---

By the methods of
force closure,
optimization and finite
element modeling

Kumar et
al.

1999

Designing a fixture

---

Both GA and neural

networks

Marcelin

2001

Optimization of support
positions

---

GA

fixture configuration
analysis based on a
dynamic model

Tools used
Influence of clamping
placement is also
investigated

1.0 Introduction (Contd.,)

Author

Year

Objective

Design criteria
---

Tools used

Vallapuzha
et al.

2002

Fixture layout
optimization

GA based optimization
method

Krishnakum
ar and
Melkote

2000

Fixture layout
optimization

Minimizes the
deformation of the
machined surface due
to clamping and
machining forces over
the entire tool path

GA

Necmettin
Kaya

2005

To find the
optimal locator
and clamp
positions in 2D
workpiece

Chip removal is taken

into account while tool
forces moving on the
workpiece

GA tool

1.0 Introduction (Contd.,)

Author

Year

Objective

Design criteria
---

Tools used

Vallapuzha
et al.

2002

Fixture layout
optimization

GA based optimization
method

Krishnakum
ar and
Melkote

2000

Fixture layout
optimization

Minimizes the
deformation of the
machined surface due
to clamping and
machining forces over
the entire tool path

GA

Necmettin
Kaya

2005

To find the
optimal locator
and clamp
positions in 2D
workpiece

Chip removal is taken

into account while tool
forces moving on the
workpiece

GA tool

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REFERENCES
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REFERENCES
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Any Queries

REFERENCES

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