Static and Dynamic Analysis of

Static and Dynamic Analysis of

Machining Fixtures
Machining Fixtures
Bo Li , Graduate Research Assistant
Shreyes N. Melkote , Assistant Professor
The George W. Woodruff School of Mechanical Engineering
Georgia Institute of Technology
Sponsors: Ford Motor Company, MTAMRI
Introduction
Introduction
I Fixtures are devices used to locate and hold a
workpiece accurately during machining process.
3-2-1 Fixturing Scheme
L
1
- L
6
Workpiece-fixture locator
C
1
- C
2
Workpiece-fixture clamp
M
X
-M
Y
-M
Z
Machining forces
X
g
-Y
g
-Z
g
Inertial coordinate system
C
1
L
3
workpiece
Z
g
O
Y
g
X
g
L
2
L
1
O C
2
L
4
L
6
L
5
M
X
M
Y
M
Z
Introduction (
Introduction (
cont
cont
.)
.)
I Typically, the workpiece rotates and translates in
machining fixture due to localized deformation at
each workpiece-fixture contact. This impacts the
part quality.
X
g
Z
g
Y
g
O
workpiece
w
y

w
x

w
z

w
Y
w
X
w
Z
Desired Position
Actual Position
Workpiece Translation and Rotation Workpiece Translation and Rotation
Overall Objective
Overall Objective
I Predict contact forces in the normal and tangential
directions due to clamping and machining loads;
I Investigate the workpiece rigid body motion in the
machining fixture and its impact on final part
quality.
I Predict the onset of undesired slip and loss of
contact at workpiece-fixture interface during
machining.
I Static indeterminacy in rigid body analysis can be
resolved by including the workpiece-fixture
contact compliance.
I At each contact patch, normal force and
tangential force are
discretized into
small components.
Undeformed Workpiece
/ Fixture Element
Contact
Static Model
Static Model
x
Z
Fixture Element
Workpiece

1
i

2
i
k-th point
P
Initial Separation
P
Static Model (
Static Model (
cont
cont
.)
.)
Min W
S.t. (1) Static equilibrium
(2) Coulombs friction law
(3) Non-negative normal force
I The elastic deformation in the normal and
tangential directions is a linear summation of the
influence of all forces components acting on this
patch.
I The minimum total complementary energy
principle is used to solve the contact problem.
W=0
Experiment Work
Experiment Work
I Static model verification: Normal force at each
fixture-workpiece contact is measured using a
pressure sensitive film (Fuji prescale film).
L4 L5
L6 L7
L1
L2
L3
C1
C2
Zg
Xg
Yg
5.03N
544.43N
7.80N
631.53N
631.53N
11.92N
7.71N
357.02N
238.77N
Transducer
Locator
Workpiece
Locators

Clamp #1
Clamp #2
Baseplate
63.5
P
i
Q
yi
Q
xi
X
g
Y
g
Normal force and actual contact area map Normal force and actual contact area map
Experimental setup (top view) Experimental setup (top view)
Experiment Work (
Experiment Work (
cont
cont
.)
.)
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Comparison of measured and predicted tangential forces Comparison of measured and predicted tangential forces
Q
y i
P
i
Q
x i
I Static model verification: Locator L3 is instrumented with a three-
axis piezoelectric force transducer to measure the tangential force.
Transducer ( Transducer (Kistler Kistler 9117A) 9117A)
P
r
e
d
i
c
t
e
d

Y

t
a
n
g
e
n
t
i
a
l

f
o
r
c
e

(
N
)

Measured Y tangential force (N)
Transducer Transducer
Locator Locator
Experiment Work (
Experiment Work (
cont
cont
.)
.)
I Normal force: The maximum relative error for the
side locators ranges from 2% to 10% for three
different sets of clamping forces. The absolute error
for the bottom locators ranges from 0.12 N to 1.29
N.
I Tangential force: The maximum absolute prediction
errors are 5.93 N for X component and 0.57 N for Y
component at locator L3 .
I It is apparent from the above comparisons that the
model performs well under different clamping
forces.
Dynamic Model
Dynamic Model
I Lumped linear stiffness model.
I Inertial effects are considered.
K
y
i
K
x
i
K
z
i
workpiece
locator/clamp
x
i
z
i
y
i
o
x
i
-

y
i

-

z
i
Local Coordinate at the i
-th
Contact
Lumped stiffness is a function of: (1) workpiece-fixture material properties.
(2) workpiece-fixture contact geometry.
(3) clamping and machining loads.
Dynamic Model (
Dynamic Model (
cont
cont
.)
.)
Newton-Euler equations of motion
Machining
forces M(t)
P
T
Stick/slip
(Coulomb friction)
P
P
h
Complementary
contact
(P 0, h 0, hP=0)

Workpiece rigid body motion q(t)

Dynamic Model Simulation
Dynamic Model Simulation
Intermittent contact and
stick/slip transition at clamp C1
I 25.4mm wide slot machining condition: (1) spindle speed = 660rpm; (2) axial
depth of cut = 6.35mm, (3) feed rate = 7.6mm/sec. (4) clamping force c
1
=
266.88N, c
2
= 889.60N.
Contact break region Slip region
Stick region

0
5
10
15
20
25
30
35
40
45
50
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
friction force normal force ratio
Sampling #
F
r
i
c
t
i
o
n

&

n
o
r
m
a
l

f
o
r
c
e
(
F
r
i
c
t
i
o
n

&

n
o
r
m
a
l

f
o
r
c
e
(
N
)
N
)
R
a
t
i
o

b
e
t
w
e
e
n

f
r
i
c
t
i
o
n

&

n
o
r
m
a
l

f
o
r
c
e
R
a
t
i
o

b
e
t
w
e
e
n

f
r
i
c
t
i
o
n

&

n
o
r
m
a
l

f
o
r
c
e
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
0
0.005
0.01
0.015
0.02
0.025
0.03
R
e
s
u
l
t
a
n
t

t
r
a
n
s
l
a
t
i
o
n

(
m
m
)
Time (s)
Dynamic Model Simulation (
Dynamic Model Simulation (
cont
cont
.)
.)
I Workpiece rigid body resultant translation and
rotation about x
g
, y
g
and z
g
axis during machining:
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
-0.02
-0.015
-0.01
-0.005
0
0.005
0.01
0.015
0.02
W
o
r
k
p
i
e
c
e

R
o
t
a
t
i
o
n


(
d
e
g
r
e
e
)
Time (s)
X
g
Z
g
Y
g
Conclusion
Conclusion
I The static model can accurately predict the
magnitude of the inwardly directed normal forces,
and the magnitude and direction of the tangential
force at each contact patch.
I Localized deformation at each contact and the
workpiece rigid body motion due to the static
loading can be determined.
I The dynamic model can predict the workpiece rigid
body motion in the fixture due to dynamic loading
while explicitly accounting for contact/no contact
and stick/slip conditions.
Ongoing/Future Work
Ongoing/Future Work
I Incorporate the impact of frictional damping and
other energy dissipation mechanisms into the
model.
I Eliminate the workpiece-fixture system vibration
due to the dynamic loading through proper friction
damping.
I Develop an efficient fixture design strategy to yield
the optimum fixture layout and corresponding
optimum clamping force(s) based on dynamic
model.