An integrated finite element method, response surface methodology, and evolutionary techniques for modeling and optimization of machining fixture layout for 3D hollow workpiece geometry

Sundararaman, K. A.; Padmanaban, K.; Sabareeswaran, M.; Guharaja, S.

doi:10.1177/0954406216668208

Cited by 10 publications

(7 citation statements)

References 34 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The contact stiffness matrix, K T . can now be calculated by using equation (11). The displacement of the contact point in each direction is proportional to the locator reaction force in the same direction and the effects of other components are ignored.…”

Section: Methodsmentioning

confidence: 99%

“…Proper design of the fixture layout can minimize vibrations in the machining process, because the arrangement of fixture directly influences the dynamics of the fixture-workpiece system. 9 In this way, Demeter 10 and Sundararaman et al 11,12 proposed an algorithm for the optimal arrangement of constraint components. The idea of small displacements was presented to model the deviation of the workpiece due to the geometric changes of the fixture.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Investigation of the stability and contact stiffness of workpiece inside fixture in different machining conditions

Sohrabifard

Nategh

2023

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

The dynamic stability of machining processes is influenced by the dynamic stability of the workpiece and fixture assembly. This effect has not yet been sufficiently considered. Achieving dynamic stability by simply applying a large amount of clamping force is a basic method and involves damages such as elastic deformation of relatively thin workpieces, damage to the clamping surfaces, and high wear of fixture components resulting in malfunction. In spite of this, to the best knowledge of the present authors, the contact stiffness between workpiece and fixture as an influencing parameter has not been sufficiently paid attention by researchers and these parameters have not been taken into account in the equations of dynamic stability. The contact stiffness itself is influenced by the machining parameters. In the present study, the changes in contact stiffness in different machining conditions are investigated as a partial undertaking to fill the gap existing in the modeling of the machining dynamics. In this paper, by defining the mathematical model of the workpiece-fixture system and calculating the matrices of contact stiffness and fixture stiffness, the results of changes in various machining parameters in the stiffness of the workpiece-fixture system have been investigated. The results showed that high contact stiffness cannot be provided simply by applying the maximum force of the clamps. Rather, by increasing the spindle speed, the contact stiffness will increase significantly. Furthermore, by increasing the spindle speed, further increase in the contact stiffness will be achieved with lower feed rates, which will not be economically viable.

show abstract

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Investigation of the stability and contact stiffness of workpiece inside fixture in different machining conditions

Sohrabifard

Nategh

2023

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

show abstract

“…Finally, to immobilize the translational DOF along x-axis and clockwise rotational DOF along z-axis, the workpiece is rested on one point of the adjacent side. The modular fixture design used in machining minimizes the need for the single and specific purpose fixtures because of the standardization of the elements used in modular fixtures (Sundararaman et al, 2017). The fixture design can be achieved using semi-automated method that combines rule-based reasoning and case-based reasoning methods (Yang et al, 2017), whereas automation of fixture design is adopted to define the setup, setup sequence and conceptual-based fixtures design.…”

Section: Introductionmentioning

confidence: 99%

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

Ramachandran

Surendarnath²,

Dharmalingam³

2020

View full text Add to dashboard Cite

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.

show abstract

“…7 A sudden increase of tool load during the machining of concave corners can result in several undesired consequences, for instance vibration, raised roughness parameters of the machined surface, increased residual stress, shorter tool life or even tool breakage. 8 Furthermore, radial immersion is in a direct relation with the cutter engagement angle 9 and the cutting force, 10 both of which values have a decisive role in the stability of the cutting process . It is also well-known that the threat of vibration is one of the most important limiting factors in machining parameters selection.…”

Section: Introductionmentioning

confidence: 99%

A discrete simulation-based algorithm for the technological investigation of 2.5D milling operations

Jacsó

Szalay

Jáuregui-Correa

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

Many applications are available for the syntactic and semantic verification of NC milling tool paths in simulation environments. However, these solutions – similar to the conventional tool path generation methods – are generally based on geometric considerations, and for that reason they cannot address varying cutting conditions. This paper introduces a new application of a simulation algorithm that is capable of producing all the necessary geometric information about the machining process in question for the purpose of further technological analysis. For performing such an analysis, an image space-based NC simulation algorithm is recommended, since in the case of complex tool paths it is impossible to provide an analytical description of the process of material removal. The information obtained from the simulation can be used not only for simple analyses, but also for optimisation purposes with a view to increasing machining efficiency.

show abstract

An integrated finite element method, response surface methodology, and evolutionary techniques for modeling and optimization of machining fixture layout for 3D hollow workpiece geometry

Cited by 10 publications

References 34 publications

Investigation of the stability and contact stiffness of workpiece inside fixture in different machining conditions

Investigation of the stability and contact stiffness of workpiece inside fixture in different machining conditions

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

A discrete simulation-based algorithm for the technological investigation of 2.5D milling operations

Contact Info

Product

Resources

About