Welding Fixture Design Research Articles

Automated design evolution for parametric design applied on computer-aided welding fixture designs

Design engineers are required to deliver design solutions by a fixed deadline. Increasing demand for shortening lead time limits the exploratory and creative freedom of the designer. This paper proposes an automated design system that can substitute part of the repetitive and standardized tasks in the design process, increasing efficiency and shifting the design engineer's efforts to creative work. Computer Aided Welding Fixture Design is an engineering domain increasingly being pressed for shortening lead time. Welding Fixture Designs are multi-part structures that secure an assembly product during a welding process. The compact and complex assembly product to be fixed and welded presents a configuration and geometric challenge for the fixture regarding sequence, collisions, tolerances, welding path, human interaction, etc. This paper presents the welding fixture design problem in its general form. To describe the freedom of automation, the paper introduces the term decision space as the subset of a design space feasible by automation. Depending on the desired outcome, the decision space can be exploited through various strategies and automation approaches. This paper presents one of these approaches by implementing an evolutionary algorithm to the parametric fixture design problem of the use case. The results show reduced engineering efforts and the potential for expanding the exploratory spectrum of design proposals during conceptualization.

Parametric design evolution for production setups; a case study for welding fixtures

Automated design evolution and optimization are concepts of utmost interest to the industry for reducing design time and cost. This paper addresses the development of an automated design solution based on an evolutionary algorithm for a parametric design problem. The design problem addresses welding fixture designs as an integrated geometric design and configuration problem. The suggested automation approach is based on the parameterization of the fixture geometry and the welding process to minimize collisions across moving and static bodies during the welding operation. The aim is to produce a welding fixture design simulation that can be adjusted for specific requirements based on expert knowledge without re-iterating the entire composition of the problem. The modularity is demonstrated by modifications of the design problem formulation aimed at altering the exploration spectrum and design proposals of the welding fixture. An early system integration shows a reduction of designer efforts to 30% compared to a manual process, with an increase in overall process time due to software computational times.

Structural design of high-precision fixture for laser welding: A review

Due to the high energy density, fast welding speed and non-contact welding, laser welding technology can be used to weld key components with complex curved surfaces. However, narrow work-piece gaps and high matching accuracy are required in laser welding, which increases the difficulty of welding. For this reason, the design of high-precision fixture has become a research hotspot. The difference between laser welding fixture and traditional welding fixture is that laser welding fixture is more complex in structure, requires high precision and needs to apply pressure on the weld. This paper discussed the structural characteristics of fixed, rotating and mobile welding fixture, and analyzed the work-piece shape, welding requirements and production mode. Laser welding fixture design engineers can quickly design the fixture according to product requirements, and refer to the structural type and design method of tooling. It not only improves the design efficiency of fixture, but also improves the processing efficiency and accuracy of welding. Finally, the challenges of structural design in laser welding fixture are pointed out. It provides a direction for the development in the structural design of laser welding fixture in the future.

Utilizing the 3D modeling technology to design a welding fixture

The article discusses utilizing the 3D modeling technology to design a welding fixture for the mechanical engineering industry. To improve the efficiency of the design process, we used the NX computer-aided design (CAD) system as a design tool. We describe the process of developing 3D models for individual components of a welding fixture with the said system. The possibilities of utilizing the created 3D model to analyze the finished product in kinematics by means of the NX system are considered. An algorithm to compute the parameters of the welding fixture using the finite element analysis (FEA) is described. As evidenced from practice, utilizing the 3D modeling technology allows design engineers to significantly reduce the time spent on a welding fixture design and implementation at a machine-building enterprise.

Transient Thermal Analysis of Welding Fixtures Design

This paper presents the design and analysis of welding fixtures based on transient thermal analysis. Welding fixtures is designed to hold and support the workpiece securely during the welding process. The heat transformation from the workpiece could lead the temperature rises and impacts to the welding fixtures. Therefore, the study introduces the development of welding fixtures as one of a safety measure prevents the welder from injury while handling welding process. The conceptual design of welding fixtures and material were applied to conduct the simulation. Transient thermal analysis was performed on temperature and total heat flux by using computer aided engineering software. The result shows the analysis of equivalent stress, total deformation, factors of safety, fatigue life and fatigue damage. Furthermore, the equivalent stress failure theory used to predict yielding in welding fixture design. The design of welding fixtures and material selection were proposed to hold and support the workpiece securely.

Based on CATIA Car Side Welding Fixture Design and Research

Based on using CATIA tools for car side around the welding jig are studied, by means of CATIA platform welding jig design, according to the design flow chart, produce drawings, it is advantageous to the reasonable arrangement of assembly line production, facilitate balanced location time, reduce the non-production season with lower production cost, improve the quality of automobile body design efficiency and design purpose.

Design of the Welding Fixture for the Rear Headrest Bracket of Audi

The article deals with the welding fixture design for the rear headrest bracket of Audi. The fixture has to ensure the right position of individual components, because well done weld is the necessity of passenger ́s and transport safety. As the first, the 3D model of products was created then the fixture (and its components) was designed and at last the virtual model of the welding table for automated production was prepared in software Autodesk Inventor Professional. On the base of the model, the real fixture was manufactured and its functionality was verified in real production. The efficiency of the whole welding process increased several times in comparison with the previous hand welding activities. The initial costs invested in the automated process start-up have returned very quickly.

Welding Deformation Controlling for the Truck Rack Girder

This paper aims at the research on deformation control technology in truck rack girder. Welded deformation is minished through special welding fixture design and welding process control, thus to improve the size precision of the truck rack girder and ensure the running safety of the vehicle.

Study of Computer-Aided Design Process and Methods Based on Welding Fixture

Although various computer-aided fixture design (CAFD) systems have been developed to assist the designer during the various stages of fixture design, most of previous computer aided fixture design research has mainly concentrated on machining fixtures rather than welding fixtures. The development of complicated computer aided welding fixture design (CAWFD) system has received much less attention. Welding fixture can ensure welding dimension, improve assembly precision and efficiency. It can prevent the welding deformation. The function of welding fixture was introduced in this paper. The computer-aided welding fixture design workflow was developed. The design steps include the project creation, setup design, Orientation and position determination, fixture plan design, fixture configuration design, fixture design verification and fixture design output. The classification of welding fixture component has been demonstrated. Information tree and the database tables to save the unit information are designed. The unit information retrieval menu and interface based on UG, Visual C++ and database is realized.

Construction and Expression of Database for Computer-Aided Welding Fixture Design (CAWFD) Systems

Welding fixture can ensure welding dimension, improve assembly precision and efficiency. It can prevent the welding deformation. The function of welding fixture was introduced in this paper. The Classification of welding fixture component was described. Information tree and the database tables to save the unit information are designed. The unit information retrieval menu and interface based on UG, Visual C++ and database is realized.

Case based reasoning method for computer aided welding fixture design

This paper presents a case-based reasoning (CBR) method for welding fixture design, a critical issue in the manufacturing of large and complicated equipment. However, previous fixture design research has mainly focused on machining fixtures rather than welding fixtures. In this paper, an approach of data abstraction for fixture design information representation is proposed, first to systemize and manage myriads of fixture related resources, e.g., past fixture design solutions, fixture units depository. Based on this approach, a multi-level CBR method for welding fixture design is then presented. This method could help designers, by referencing previous design cases, to make a conceptual fixturing solution quickly and, finally, finish the detailed solution of fixture design.