Simulation and optimization of machining fixture layout for minimum workpiece deformation using doe and fem

Abstract

In the machining industry, it is necessary to produce the parts in specified quality with accuracy. The dimensional and form errors are affecting the quality and accuracy of the products during a machining operation. These errors are controlled by minimizing the workpiece elastic deformation caused by machining force acting on the component. Fixtures are key elements in modern machining, assembly, and inspection operations, machining fixtures plays the main role in the productivity and quality of the finished product. During the machining process, the fixtures are used to hold the workpiece and maintain the required position of the part to be machined. Locating elements are used to position the workpiece and clamping elements are used to hold the component during the machining operation, these locating and clamping elements are generally called fixture elements. The process of placing the locating and clamping elements is known as fixture layouts. The minimum workpiece deformation during machining operation can be achieved through the optimal design of fixture layouts, which provides a way to avoid machining errors. newlineIn this research work, two types of analysis are conducted for minimum workpiece deformation. They are, analysis of workpiece-fixture elements contact region as surface contact using various fixturing schemes and optimization of fixture layout for various workpiece - machining conditions. The workpiece geometries are developed using SOLIDWORKS software. The workpiece elastic deformation under machining and clamping condition is simulated using finite element solver ANSYS workbench feature. newline