Fixturing technology and system for thin-walled parts machining: a review

Li, Haibo; Wang, Chengxin; Li, Te; Bo, Qile; Li, Kuo; Wang, Yongqing

doi:10.1007/s11465-022-0711-5

“…Most of the vibration suppression work has been centered around ancillary devices that attach to flexible, or re-configurable, fixtures in order to provide higher damping properties by means of tuned mass dampers, particle based dampers and eddy current damping [6]. Few studies have directly targeted workholding layouts with vibration avoidance as a key metric [7].…”

Section: Computer Assisted Fixture Design ( Cafd)mentioning

confidence: 99%

Unsupported machining fixture layout optimisation

Soto,

Sims,

Ozturk

et al. 2024

J. Phys.: Conf. Ser.

0

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It is well established that excessive vibrations in machining operations hinder productivity and quality of the components being made. In these environments it is common to encounter self-excited vibrations due to the dynamic response characteristics of the cutting tool and workpiece; referred to as regenerative chatter. To suppress these effects, conventional practices provide the workpiece with as much support as possible and therefore commonly require custom-built fixturing bases and several manual intervention stages. In contrast, for modern reduced fixturing approaches, the workpiece is minimally-held, with the benefits of reduced setup times, lower fixturing and inventory costs, and improved access to the workpiece thereby avoiding multi-stage setups. However, minimal fixturing reduces support of the workpiece, and so vibration becomes a greater challenge, along with the subsequent detrimental effects to part quality and material removal rate (mrr). This paper sets out to determine an optimisation methodology for layout configurations that maximise milling depths of cut whilst achieving dynamic stability; by means of FEA model-based simulations and particle swarm optimisation (pso) methods. The optimisation algorithm is then tested on simplified setups and compared to exhaustive searches. It is shown that optimal results can differ from standard practice, and despite the comparative reduction in workpiece stiffness to a traditional approach is mostly unavoidable, careful placement of workholding elements can reportedly improve cutting conditions and increase dynamic stability within an unsupported environment.

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“…For example, wax 12 or ice 13 are filled in the deep and narrow space to provide extra support as they could easily be removed by the cutting tool. Recent overviews related to fixtures can be found in 14 , 15 . Additionally, high-speed machining (HSM) is popularly applied for the machining of aircraft structural components characterized by deep and thin-walled structures.…”

Section: Introductionmentioning

confidence: 99%

Numerical evaluation of cutting strategies for thin-walled parts

Lassila,

Svensson,

Wang

et al. 2024

Sci Rep

1

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Static form errors due to in-process deflections is a major concern in flank milling of thin-walled parts. To increase both productivity and part geometric accuracy, there is a need to predict and control these form errors. In this work, a modelling framework for prediction of the cutting force-induced form errors, or thickness errors, during flank milling of a thin-walled workpiece is proposed. The modelled workpiece geometry is continuously updated to account for material removal and the reduced stiffness matrix is calculated for nodes in the engagement zone. The proposed modelling framework is able to predict the resulting thickness errors for a thin-walled plate which is cut on both sides. Several cutting strategies and cut patterns using constant z-level finishing are studied. The modelling framework is used to investigate the effect of different cut patterns, machining allowance, cutting tools and cutting parameters on the resulting thickness errors. The framework is experimentally validated for various cutting sequences and cutting parameters. The predicted thickness errors closely correspond to the experimental results. It is shown from numerical evaluations that the selection of an appropriate cut pattern is crucial in order to reduce the thickness error. Furthermore, it is shown that an increased machining allowance gives a decreased thickness error for thin-walled plates.

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“…For example, wax [12] or ice [13] are filled in the deep and narrow space to provide extra support as they could easily be removed by the cutting tool. Recent overviews related to fixtures can be found in [14,15].…”

Section: Introductionmentioning

confidence: 99%

Numerical evaluation of cutting strategies for thin-walled parts

Lassila¹,

Svensson

²

,

Wang³

et al. 2023

Preprint

0

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Static form errors due to in-process deflections is a major concern in flank milling of thin-walled parts. To increase both productivity and part geometric accuracy, there is a need to predict and control these form errors. In this work, a modelling framework for prediction of the cutting force-induced form errors, or thickness errors, during flank milling of a thin-walled workpiece is proposed. The modelled workpiece geometry is continuously updated to account for material removal and the reduced stiffness matrix is calculated for nodes in the engagement zone. The proposed modelling framework is able to predict the resulting thickness errors for a thin-walled plate which is cut on both sides. Several cutting strategies and cut patterns using constant z-level finishing are studied. The modelling framework is used to investigate the effect of different cut patterns, machining allowance, cutting tools and cutting parameters on the resulting thickness errors. The framework is experimentally validated for various cutting sequences and cutting parameters. The predicted thickness errors closely correspond to the experimental results. It is shown from numerical evaluations that the selection of an appropriate cut pattern is crucial in order to reduce the thickness error. Furthermore, it is shown that an increased machining allowance gives a decreased thickness error for thin-walled plates.

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Fixturing technology and system for thin-walled parts machining: a review

Cited by 10 publications

References 158 publications

Unsupported machining fixture layout optimisation

Unsupported machining fixture layout optimisation

Numerical evaluation of cutting strategies for thin-walled parts

Numerical evaluation of cutting strategies for thin-walled parts

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