Elastic mechanics-based fixturing scheme optimization of variable stiffness structure workpieces for surface quality improvement

Li, Guilong; Du, Shichang; Huang, Delin; Zhao, Chen; Deng, Yafei

doi:10.1016/j.precisioneng.2019.01.004

Cited by 52 publications

(17 citation statements)

References 55 publications

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“….,D} are the random indexes. Though k is a random index, it should to be different from i. R ij is a random number chosen between (Li et al, 2019). It is mandatory that the position of fixturing elements obtained in the population should lie within the range of the variables and the values that exceed the range are set to their boundary values.…”

Section: Search Of Employed Beementioning

confidence: 99%

“…To locate the workpiece, all the DOF's are to be fixed except the three translational DOF (Àx, Ày and Àz) which is accomplished by 3-2-1 principle. The clockwise and anticlockwise rotational DOF along x and y axes along with the translational DOF along z-axis can be arrested by resting the workpiece on three non-collinear points of the bottom surface (Li et al, 2019;Hao et al, 2018). The translational DOF along y-axis and anticlockwise rotational DOF along z-axis are fixed by resting the workpiece on two points of side surface.…”

Section: Introductionmentioning

confidence: 99%

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Engine-bracket drilling fixture layout optimization for minimizing the workpiece deformation

Ramachandran

Surendarnath²,

Dharmalingam³

2020

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Purpose Fixture layout design is concerned with immobilization of the workpiece (engine mount bracket) during machining such that the workpiece elastic deformation is reduced. The fixture holds the workpiece through the positioning of fixturing elements that causes the workpiece elastic deformation, in turn, leads to the form and dimensional errors and increased machining cost. The fixture layout has the major impact on the machining accuracy and is the function of the fixturing position. The position of the fixturing elements, key aspects, needed to be optimized to reduce the workpiece elastic deformation. The purpose of this study is to evaluate the optimized fixture layout for the machining of the engine mount bracket. Design Methodology Approach In this research work, using the finite element method (FEM), a model is developed in the MATLAB for the fixture-workpiece system so that the workpiece elastic deformation is determined. The artificial neural network (ANN) is used to develop an empirical model. The results of deformation obtained for different fixture layouts from FEM are used to train the ANN and finally the empirical model is developed. The model capable of predicting the deformation is embedded to the evolutionary optimization techniques, capable of finding local and global optima, to optimize the fixture layouts and to find the robust one. Findings For efficient optimization of the fixture layout parameters to obtain the least possible deformation, ant colony algorithm (ACA) and artificial bee colony algorithm (ABCA) are used and the results of deformation obtained from both the optimization techniques are compared for the best results. Research Limitations Implications A MATLAB-based FEM technique is able to provide solutions when the repeated modeling and simulations required i.e. modeling of fixture layouts (500 layouts) for every variation in the parameters requires individual modeling and simulation for the output requirement in any FEM-based software’s (ANSYS, ABACUS). This difficulty is reduced in this research. So that the MATLAB-based FEM modeling, simulation and optimization is carried out to determine the solutions for the optimized fixture layout to reach least deformation. Practical Implications Many a time the practicability of the machining/mechanical operations are difficult to perform costly and time-consuming when more number of experimentations are required. To sort out the difficulties the computer-based automated solution techniques are highly required. Such kind of research over this study is presented for the readers. Originality Value A MATLAB-based FEM modeling and simulation technique is used to obtain the fixture layout optimization. ANN-based empirical model is developed for the fixture layout deformation that creates a hypothesis for the fixture layout system. ACA and ABCA are used for optimizing the fixture layout parameters and are compared for the best algorithm suited for the fixture layout system.

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Section: Search Of Employed Beementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Engine-bracket drilling fixture layout optimization for minimizing the workpiece deformation

Ramachandran

Surendarnath²,

Dharmalingam³

2020

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“…e positioning performance reference coefficient can be used to evaluate the performance of the fixture to constrain the position of the workpiece [17,18] and to find the optimal position of each positioning point based on the coefficient. Based on the research of combined genetic algorithm [19,20], the optimal positioning method of the workpiece based on the genetic material library is found, and the surface quality in the workpiece clamping is improved. Song and Rong [21] established a matrix for the position parameters, solved the rank of the matrix to analyze the positioning constraint of the workpiece, and obtained the DOF property of the constraint, which can accurately obtain the scheme to meet the machining requirements of the workpiece processing.…”

Section: Introductionmentioning

confidence: 99%

Geometric Theorems and Application of the DOF Analysis of the Workpiece Based on the Constraint Normal Line

Luo

Wang

Yan

2021

Advances in Materials Science and Engineering

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Aiming at the problem of judging the degree of freedom (DOF) of the workpiece in the fixture by experience, it is difficult to adapt to the analysis of the DOF of some singular workpieces. The workpiece and the fixture are used as rigid bodies, and the workpiece is allowed to move in the plane or space under the constraints of the fixture positioning point, and a set of geometric theorems for judging the DOF and overconstraint of the workpiece can be derived according to the difference in the position of the instantaneous center of the workpiece speed. The judgment of the DOF and overconstraint of the workpiece is abstracted into rules with universal meaning, which effectively overcomes the limitations of existing methods. The research results show that (1) the DOF and overconstraint of the workpiece in the fixture depend entirely on the number of positioning normal lines of the workpiece and their geometric relationship; (2) the necessary and sufficient condition for limiting the DOF of rotation of the workpiece around a certain axis is that the workpiece has a pair of parallel normal lines in the vertical plane of the axis. Using geometric theorems to judge the DOF of the workpiece is more rigorous, simple, and intuitive, which is convenient for computer-aided judgment and the reasonable layout of the positioning points of the workpiece, which can effectively avoid the misjudgment of the DOF and unnecessary overpositioning when the complex workpiece is combined and positioned on different surfaces. Several examples are used to verify the accuracy of the method and correct unreasonable positioning schemes.

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“…The problem of ensuring the correct stiffness of the machine tool foundation for machining large-size details has been solved for example by the optimized sequence of tightening the anchor bolts for a given configuration of the machine bed and anchor system 13 . However, in order to improve the surface quality during the face milling process, it is more important to optimize the mounting pattern of the workpiece on the machine table based on the structure of variable stiffness 14 . Also, various workpiece holders can affect energy consumption, tool wear, and surface quality in milling operations 15 .…”

Section: Introductionmentioning

confidence: 99%

A Method of Predicting The Best Conditions for Clamping a Large-Size Workpiece in Order To Reduce Vibrations in The Milling Process

Kaliński

Stawicka-Morawska

Galewski

et al. 2021

Preprint

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The paper presents an innovative method of solving the problem of vibration suppression during milling of large-size details. It consists in searching for the best conditions for clamping the workpiece based on a rapid modal identification of the dominant natural frequencies only and requires repetitive changes in the tightening torque of the clamping screws. Then, by estimating the minimum work of the cutting forces acting in the direction of the width of the cutting layer, it is possible to predict the best fixing of the workpiece. Application of the method does not require the creation and identification of a computational model of the process or preliminary numerical simulations. The effectiveness of this method was confirmed by the evaluation of the Root Mean Square (RMS) of the vibration level in the time domain observed during the actual face milling process.

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Elastic mechanics-based fixturing scheme optimization of variable stiffness structure workpieces for surface quality improvement

Cited by 52 publications

References 55 publications

Engine-bracket drilling fixture layout optimization for minimizing the workpiece deformation

Engine-bracket drilling fixture layout optimization for minimizing the workpiece deformation

Geometric Theorems and Application of the DOF Analysis of the Workpiece Based on the Constraint Normal Line

A Method of Predicting The Best Conditions for Clamping a Large-Size Workpiece in Order To Reduce Vibrations in The Milling Process

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