Fixture Optimization in Turning Thin-Wall Components

Croppi, Lisa; Grossi, Niccolò; Scippa, Antonio; Campatelli, Gianni

doi:10.3390/machines7040068

Cited by 15 publications

(7 citation statements)

References 33 publications

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“…To overcome these difficulties, they applied single pressure chains that generate a pressure stress of 800 KPa or more under a moderate magnetic field. Croppi et al [34] presented a general methodology for the optimization of reinforcement in cases of turning thin-wall workpieces. Starting from the geometry of the workpiece and the tool path, by combining the FE model, the geometric error model, and the fixture model, the optimal configuration of the fixture is calculated as the one that can guarantee the imposed tolerance and stable machining with a minimum number of additional supports.…”

Section: Introductionmentioning

confidence: 99%

Application of Natrium Silicate as a Phase Change Material in Fixture Design

2023

Teh. vjesn.

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The paper presents the results of theoretical, numerical, and experimental research related to the analysis of the possibility of using natrium silicate in the design of fixtures. Two possible aggregate states of natrium silicate (liquid and solid aggregate state) with its strong adhesion to metal materials as well as a number of other properties were used, and it was proven that it can find significant applications in the fixture of workpieces, especially when machining workpieces with thin walls and complex contours, as well as pockets with a large pocket depth to wall thickness ratio. The results of the performed analyses indicate a great potential for the application of natrium silicate as a new phase-change material. A mixture of natrium silicate and non-metallic materials such as fireclay flour acquires the properties of stone by hardening, while it decomposes when in contact with water. This mixture can solve the problems of technological operations on workpieces with thin walls and closed contours, known as deep pockets. The research results related to the proposed machining method were verified by using the example of machining a deep pocket with a complex contour. After the process of machining the complex contour of the thin-wall workpiece, the meanwall thickness value of 0,144 ± 0,004 mm at the meanpocket depth value of 60,052 ± 0,058 mm was obtained. The obtained mean values of the pocket depth and wall thickness as well as their mutual relationship, indicate the possibility of the practical application of natrium silicate as a phase-change material in the fixture design for machining thin-wall workpieces of complex geometry.

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Section: Introductionmentioning

confidence: 99%

Application of Natrium Silicate as a Phase Change Material in Fixture Design

2023

Teh. vjesn.

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“…The consuming time for clamping the complex cabins is longer than its processing time, and the utilization rate of most machining equipment is less than 30%. It can be seen that the clamping tooling is an important part to affect the machining accuracy and the benchmark transmission, which directly influences product quality, production efficiency, and processing cost [6,7]. According to a study by the Boeing Company on machining deformation of four aircraft projects, the economic losses of parts rework and scrap due to machining deformation exceeded 290 million USD [8].…”

Section: Introductionmentioning

confidence: 99%

Research on Rapid and Accurate Fixture Design for Non-Intervention Machining of Complex Parts

Ding

Wang

Yuan

et al. 2022

Metals

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Aerospace parts have the characteristics of complex shape and high machining accuracy, the machining processes of which is complicated and diverse. Numerous special tooling fixtures need to be designed to ensure the smooth implementation of the machining process. In particular, the cabins of the aircraft have thin-walled, weakly rigid, complex, and special-shaped curved structures, the clamping alignment of which is difficult because of a great deal of human influence and poor versatility. In response to the above problems, off-machine clamping technology was investigated, which supports the non-intervention processing of flexible production lines. Then, a scheme suitable for accurate transmission of benchmarks was proposed. A cabin’s mathematical model of casting clamping force analysis was established. Immediately afterwards, the optimization of clamping project was realized by a finite element analysis method based on clamping force and deformation control. The off-machine clamping scheme was designed to realize rapid positioning and accurate datum transmission between flexible tooling and parts, flexible tooling, and equipment. Finally, the designed scheme was implemented through a case to verify its feasibility.

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“…Successful machining requires the use of one of the techniques to avoid chatter [30]. In practice, this is usually addressed either by reducing the dynamic compliance of the workpiece by additional reinforcement [12], damping with active or passive dampers, or by appropriate intervention in the force action of the process -either by disrupting the regenerative principle or by reducing the magnitude of the force response. In case of disturbance of the regenerative principle, either the use of gaps between lobes in high-speed machining (especially in milling [24]), speed variation in low-speed machining [16,20,2] or one of the newer methods such as regenerative compensation by active control [23], machining with ultrasonic vibration [33] or the method of time-varying longitudinal workpiece stiffness due to external force [6] .…”

Section: Introductionmentioning

confidence: 99%

Model of Force Interaction for Stability Prediction in Turning of Thin-Walled Cylindrical Workpiece

Falta

Sulitka²,

Janota³

et al. 2022

Preprint

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Turning of the thin-walled cylindrical workpiece is technologically highly demanding process due to the high flexibility of the workpiece . In this paper, a mathematical treatment of integral-based model of the cutting force which takes into account feed, cutting speed, depth of cut and tool nose radius leading to a model of tool- workpiece interaction is presented. The force interaction together with the compliant workpiece dynamics leads to a machining stability formulation. The effect of the aforementioned parameters on characteristic exponents is calculated and validated by comparison with experimentally identified exponents. One of the outputs with immediate practical value is identification of the process damping, which is in the studied case shown to be significantly higher than structural damping of the workpiece itself. This means that without loss of reliability in stability prediction the experimental modal analysis of a given workpiece may be omitted and workpiece ' dynamics may be described only by mass and stiffness matrices which can be easily and reliably obtained by a finite element analysis.

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Fixture Optimization in Turning Thin-Wall Components

Cited by 15 publications

References 33 publications

Application of Natrium Silicate as a Phase Change Material in Fixture Design

Application of Natrium Silicate as a Phase Change Material in Fixture Design

Research on Rapid and Accurate Fixture Design for Non-Intervention Machining of Complex Parts

Model of Force Interaction for Stability Prediction in Turning of Thin-Walled Cylindrical Workpiece

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