Prediction of workpiece deformation in a fixture system using the finite element method

Siebenaler, Shane P.; Melkote, Shreyes N.

doi:10.1016/j.ijmachtools.2005.04.007

Cited by 99 publications

(35 citation statements)

References 14 publications

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“…The aim of this work is to (1) predict part distortion after machining and (2) propose some explanations for the phenomena occurring during this process contributing to part distortion (i.e., finding a relation between residual stress distribution, part distortion, and clamping). To achieve these objectives, it is necessary to (1) determine the initial residual stress field induced by heat treatment; (2) develop a distortion model considering the initial residual stress field, machining clamping forces [10][11][12][13], and sequence effects (i.e., the effect of the distorted shape at a given stage on the material removal from the following machining stage); (3) design and produce a special experimental device with force sensors integrated in the clamping system; and (4) validate the numerical clamping force using this fastening device.…”

Section: Introductionmentioning

confidence: 99%

Instrumented clamping device and numerical simulations to study machining distortion

Cherif

Cotton

Poulachon

et al. 2019

Int J Adv Manuf Technol

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Machining part distortion is due to residual stresses induced by previous manufacturing processes. This study aims to evaluate the influence of machining conditions on AISI 316L plate distortion. Therefore, a special experimental device with force sensors integrated in the clamping system and numerical model of distortion were developed. Residual stresses due to previous machining processes were measured using a layer removal method and neutron diffraction technique. Then, distributions of these residual stresses were integrated in a developed model of machining distortion, which considers the clamping and machining sequence effects after each stage of the toolpath. A comparison of the experimental and numerical results revealed that the finite element method can adequately predict machining distortion. The results also suggest that clamping and machining sequence can affect part distortion.

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Section: Introductionmentioning

confidence: 99%

Instrumented clamping device and numerical simulations to study machining distortion

Cherif

Cotton

Poulachon

et al. 2019

Int J Adv Manuf Technol

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show abstract

“…Siebenaler and Melkote [5] presented a fixture-workpiece model using finite element method (FEM) to investigate the influence of various parameters on workpiece deformation, including the compliance of the fixture body, contact friction, and mesh density. Prabhaharan et al [6] presented a fixture layout optimization method that used genetic algorithm (GA) and ant colony algorithm (ACA) separately.…”

Section: Introductionmentioning

confidence: 99%

Fixture Layout Design Based on a Single-Surface Clamping with Local Deformation

Tadić¹,

Todorovič²,

Novkinic³

2015

Int. j. simul. model.

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Proposed in this paper is a novel approach to fixture layout design. The contact interface between workpiece and fixture is reduced to a single workpiece surface. This allows reliable machining of the remaining five workpiece surfaces in a single setup. Workpiece clamping is performed by inserting special elements into prepared auxiliary openings on the workpiece. Clamping is thus reduced to indenting of sharp clamping element tips into the workpiece surface. Shallow indenting is performed on surfaces which have no practical function. Special device was designed to allow experimental investigation. Experimental results point towards the efficiency of the proposed approach. Workpiece displacements were small during machining and allowed the required machining accuracy. Furthermore, the results obtained during machining indicate high surface quality.

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“…Deng and Melkote [17] presented a model-based framework for determining the minimum required clamping force to ensure the dynamic stability of a fixtured workpiece during machining. Siebenaler and Melkote [18] presented a fixtureworkpiece model using FEA to investigate the influence of various parameters on workpiece deformation, including the compliance of the fixture body, contact friction, and mesh density. Ratchev et al [19] addressed this knowledge gap by proposing a fixture-workpiece behaviour prediction methodology that utilized commercial FEA software for the prediction of complex fixture-workpiece behaviour during machining processes.…”

Section: Introductionmentioning

confidence: 99%

Modelling of Dynamic Compliance of Fixture/Workpiece Interface

Todorovič¹,

Vukelić²,

Tadić³

et al. 2014

Int. j. simul. model.

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In this paper, the compliance of interface between fixture elements and workpiece is theoretically and experimentally investigated. The proposed theoretical model allows modelling of the behaviour of all kinds of interfaces between fixture elements and workpiece, under arbitrary dynamic loads. Workpiece displacement relative to fixture element was determined by analytical solution of the Lagrange differential equations of motion. Interface stiffness and damping coefficient were determined experimentally. The results of experimental investigation confirm the claims of theoretical model.

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Prediction of workpiece deformation in a fixture system using the finite element method

Cited by 99 publications

References 14 publications

Instrumented clamping device and numerical simulations to study machining distortion

Instrumented clamping device and numerical simulations to study machining distortion

Fixture Layout Design Based on a Single-Surface Clamping with Local Deformation

Modelling of Dynamic Compliance of Fixture/Workpiece Interface

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