Design, Optimization, and Analysis of Machining Fixture Layout under Dynamic Conditions

Abstract

Abstract: This paper presents a study on the optimization of fixture layout design in multi-operation machining processes to improve the dimensional accuracy, surface finish, and productivity of manufacturing industries. The study focuses on the role of fixture elements such as locators and clamps in holding, securing, and restraining the workpiece during machining operations. The improper fixture layout can increase the vibration of the fixture-workpiece system, leading to reduced accuracy and surface finish of the machined workpiece. The study employs Finite Element Method (FEM) and modal analysis to compute the natural frequencies of the fixture-workpiece system and proposes the use of a Genetic Algorithm (GA) and Particle Swarm Optimization (PSO) to optimize the fixture layout design. ANSYS 15.0 and MATLAB software are used to conduct the FEM analysis and develop the GA and PSO coding. The study also presents the validation of the proposed approach on both 2D and 3D fixtureworkpiece systems. The results show that PSO-based optimization produces better results and is identified as the suitable method for fixture layout optimization problems. The proposed approach can aid designers in minimizing machining vibration and achieving the required machining accuracy in multi-operation machining processes.