An integrated approach for Fixture Layout design and Clamping Force Optimization

Fixture design is a critical step in machining. An important aspect of fixture design is the optimization of the fixture, the primary objective being the minimization of workpiece deflection by suitably varying the layout of fixture elements and the clamping forces. Previous methods for fixture design optimization have treated fixture layout and clamping force optimization independently and/or used nonlinear programming methods that yield sub-optimal solutions. This paper deals with application of the genetic algorithm (GA) for fixture layout and clamping force optimization for a compliant workpiece. An iterative algorithm that minimizes the workpiece elastic deformation for the entire cutting process by alternatively varying the fixture layout and clamping force is proposed. It is shown via an example of milling fixture design that this algorithm yields a design that is superior to the result obtained from either fixture layout or clamping force optimization alone.

Recently, highly porous metal foams have been used to replace the traditional open-flow channels to improve gas transport and distribution in the cells. Deformation of flow plate, gas diffusion layer (GDL), and metal foam may occur during assembling. When the cell size is small, the deformation may not be significant. For large area cells, the deformation may become significant to affect the cell performance. In this study, an assembling device that is capable of applying uniform clamping force is built to facilitate fuel cell assembling and alleviate the deformation. A compressing plate that is the same size of the active area is used to apply uniform clamping force before surrounding bolts are fastened. Therefore, bending of the flow plate and deformation of GDL and metal foam can be minimized. Effects of the clamping force on the microstructures of GDL and metal foam, various resistances, pressure drops, and cell performance are investigated. Distribution of the contact pressure between metal foam and GDL is measured by using pressure sensitive films. Field-emission scanning electron microscope is used to observe the microstructures. Electrochemical impedance spectroscopy analysis is used measure resistances. The fuel cell performance is measured by using a fuel cell test system. For the cell design used in this study, the optimum clamping force is found to be 200 kgf. Using this optimum clamping force, the cell performance can be enhanced by 50%, as compared with that of the cell assembled without using clamping plates. With appropriate clamping force, the compression force distribution across the entire cell area can approach uniform. This enables uniform flow distribution and reduces mass transfer resistance. Good contact between GDL and metal foam also lowers the interface resistance. All these factors contribute to the enhanced cell performance.

Fixture layout for machining thin-walled structures plays an important role in fixture performance. This work focuses on the optimization design of machining fixture layout including clamp layout and the layout of support heads. A universal optimization methodology that can automatically generate the optimal machining fixture layout is proposed. The optimization of fixture layout is implemented based on the criteria of minimizing maximum deflection of the thin-walled workpiece while remain relatively small torque caused by the clamping tables. An evolutionary algorithm is employed to solve the fixture layout optimization for the optimal solution. The optimal position of the support heads and the layout of clamping tables obtained from this work vary along with the change of cutting force. To validate the proposed optimization methodology, a fixture layout design for a typical thin-walled structure is optimized as an example. The case study demonstrates the application of the proposed approach in the fixture layout design for thin-walled structures, which is beneficial to design an optimal fixture layout.

The effects of frictional damping on the dynamic response of a beam structure have been investigated. The frictional damping was contributed from the slip mechanisms in a ‘pseudo’ joint, that is a joint that did not take any static load. Using pseudo joints for vibration control has significant advantages over using joints that are designed both to take static load and to introduce frictional damping; because there is almost no restriction on the configuration of the pseudo joint, the undesirable side effects related to the frictional damping such as fretting corrosion of contact surfaces and loss of static stiffness are zero if the frictional damping from a pseudo joint is utilized. An ‘optimum’ clamping force was found which minimized the magnitude of the frequency response function (FRF) of the structure under excitation. A reduction of about 20 dB in the amplitudes of the FRFs was achieved by adjusting the clamping force at the joint. Frictional damping was found to be significant over the measured frequency range of 20-2000 Hz, and it was particularly effective over the range of 20-1000 Hz. The magnitudes of the FRFs of the structure were determined by the ratio of clamping force to excitation force. They were insensitive to the change of clamping force near its optimum value; also the optimum clamping force was not sensitive to small modifications to the structure. Therefore, utilizing frictional damping in pseudo joints is an effective technique for vibration control.

This paper describes the effects of the clamping force and the pre-clamping force on the fatigue strength of bolt-connection. The results obtained are as follows:(1) The types of load-deflection diagrams of bolt-connection with the clamping force were classified into cross-type and un-cross-type.(2) And also, theoretical expressions of the optimum clamping force and the pre-clamping force were inducted to the both types of the diagrams.(3) The theoretical values of the optimum clamping force nearly fitted to the experimental values.(4) The experimental values of the fatigue limits on the optimum clamping force for the M 5 bolt of bolt-connection increased about 40% against the conventional value, at mean stress σm = 30 kg/mm2.(5) The effects of the pre-clamping force on the bolt-connection were inducted with the improvements on the compressive residual stress in bolt-connection and the optimum clamping force.

This article proposes a general fixture layout design framework that directly integrates the system equation with the convex relaxation method. Note that the optimal fixture design problem is a large-scale combinatorial optimization problem; we relax it to a convex Semi-Definite Programming (SDP) problem by adopting sparse learning and SDP relaxation techniques. It can be solved efficiently by existing convex optimization algorithms and thus generates a near-optimal fixture layout. A real case study in the half-to-half fuselage assembly process indicates the superiority of our proposed algorithm compared to the current industry practice and state-of-art methods.

A review of the recent development of the machining fixture configuration/layout is presented in this paper. The literature review is mainly focused on the recently developed optimal fixture configuration under the dynamic conditions of the workpiece. In this review paper, the fixture design, fixture analysis, fixture synthesis, fixture layout design, optimization of fixture layout design, various optimization algorithms, and case studies of two- and three-dimensional workpiece geometries under dynamic conditions have been emphasized specially. The further scopes of the research are finally summarized.

Machining accuracy of thin-walled parts is easily affected by clamping and cutting deformation due to its poor stiffness. In this paper, synchronous optimization method of clamping force and cutting parameters is presented based on GA and FEM. The optimization objective is to minimize the maximum deformation and to improve the machining efficiency. GA is used to optimize cutting parameters and clamping force, and FEM is used to predict the machining deformation of the thin-walled workpiece. Finally, taking a titanium alloy thin-walled part with irregular shape as an example, the optimal clamping force and cutting parameters at every cutting position are obtained to demonstrate the feasibility of the method.

Fixture layout is the fundamental task of fixture design, to determine the number, type, and location of the basic fixturing elements of locators, supports, and clamps, as opposed to the detailed design of the fixture assembly. This paper describes an approach based on a novel technique of optimal pursuit to the layout problem. The focus of the paper is on effective fixture modeling and efficient numerical techniques for automatically generating, analyzing, and optimizing fixture layout designs for any complex-shaped 3D workpieces.

In order to assure the dimensional quaLity of compLiant sheet metal assembly, it is quite necessary to use the numerical method to simulate and analyze the assembly process before real assembly. In this paper, the finite element analysis of the whole compLiant sheet metal assembly process is reaLized in two steps: clamping force calculation and joining and springing back simulation. Clamping force is optimized so that the initial gap between parts can be closed. The joints of the two parts are simulated by DOF coupLing in ANSYS. Spring-back force, which is assumed to be equal to the optimum clamping force, is appLied on the joint points. Large displacement static analysis is run in ANSYS to calculate the displacement distribution of both clamped part and compLiant sheet metal assembly. An example of compLiant sheet metal assembly by lap joints is studied to demonstrate the finite element analysis process in this paper.

Existing force-measuring devices lack versatility in studying the dynamic coupling process between the seedling-picking device and the plug seedling pot during automatic transplanting. This research developed a universal force-measuring device featuring a centrally symmetrical clamping needle layout and a simultaneous insertion and clamping mechanism. The force-measuring device enables the flexible adjustment of the number of clamping needles (2/3/4 needles) via a modular structure. It can also modify the insertion depth and angle of the clamping needles to accommodate three specifications of plug seedlings, namely 50-hole, 72-hole, and 128-hole plug seedlings. A real-time monitoring system with dual pull-pressure sensors is integrated to precisely acquire the dynamic response curves of the clamping force (FJ) and the disengaging force (FN) of the plug seedling pot during the seedling-picking process. Taking water spinach plug seedlings as the research object and combining with EDEM-RecurDyn coupling simulation, the interaction mechanism between the clamping needle and the plug seedling pot was elucidated. The performance of the force-measuring device was verified through systematic force-measuring experiments. The main research findings are as follows: The force-measuring device designed in this study can successfully obtain the mechanical characteristic curve of the relevant seedling plug pot throughout the automatic seedling-picking process. The simulation results show high consistency with the experimental results, indicating that the force-measuring device can effectively reveal the dynamic coupling process between the seedling-picking device and the plug seedling pot. The verification experiment demonstrates that the force-measuring device can effectively quantify the mechanical properties of the of plug seedling pots under different plug seedlings specifications and different clamping needles configurations. Reducing the hole size and increasing the number of clamping needles can effectively decrease the peak value of the disengaging force (FNmax). The peak clamping force (FJmax) is approximately inversely proportional to the needle number, with the four-needle layout providing the most uniform force distribution. The force-measuring device developed in this study is functional, applicable, and versatile, offering a general force-measuring tool and a theoretical foundation for optimal seedling-picking device design.

Machining fixture layout optimization using the genetic algorithm

Optimisation of machining fixture layout under multi-constraints

Although the conventional total knee arthoplasty (TKA) planning used 2D or 3D images of the patient’s lower extremity to determine bone alignment, it was shown that good bone alignment does not always guarantee successful results due to unbalanced joint contact forces and soft tissue tension. Thus, the joint contact force balance and soft tissue tension were pre-operatively calculated using finite element analysis (FEA). Although the results of FEA are accurate, the rigid body spring method (RBSM) has introduced for the joint contact force or pressure distribution due to the high costs for FEA. In this paper, an innovative method was described to quantify the pre- and post-operative knee contact force balance using various engineering techniques, including the free-form deformation (FFD) technique, and RBSM-based cartilage contact force and ligament tension estimation algorithm. Nine cases of TKA planning were performed with three different surgical options, including over-correction of the valgus ratio of the femur, tibial plateau cutting length, and MCL release to redistribute the medial and lateral contact force balance. This method is useful as a patient-specific preoperative planning tool in TKA surgery.

Computational analysis of compressive joint stability and acromial stress associated with varied rotator cuff integrity after reverse shoulder arthroplasty.