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To calculate the minimum clamping forces required to hold the work piece, the
friction forces due to locators and clamps are considered.
The balancing force-moment equations are also used here to calculate the
clamping forces and the reaction forces due to the locators.
Most of the studies do not consider the dynamic machining forces in the fixture
optimization design to minimize the dynamic response of the work piece.
Most researchers did not consider the material removal effect in the analysis
2.1 METHODOLOGY
Machining parameters
Machining parameters
Number of flute 4
Fixture element’s
∑ F x= 0
C1+R1+R2+FX=0
∑ FY =0
C 3+R4+R5+R6+FY = 0
∑F Z =0
C3+R3+FZ =0 x
∑ ML3= 0
C 1 *53.3 + C2* 0+ C 3*50.8 +R1* 111.4 +R2* 12.7+ R 4*12.7 + R5* 114.3 +R 6*63.5+Fx*127 + F y*127+ F z*38.1 =
0 ….. E q (3)
∑ ML4= 0
C 1 *12.7 + C2* 114.2+ C 3*63.5 +R1* 114.3 +R2114.3+ R 3*12.7 + R5* 101.6 +R 6*38.1 +Fx*12.7+ F y*114.3+ F
*114.3 = 0 ….. E q (4)
z
∑ ML5 = 0
C 1 *12.7 + C2* 12.7+ C 3*63.5 +R1* 19.05 +R2* 114.3+ R 3*114.3 + R4* 101.6 +R 6*63.5 +Fx*12.7 + F y*12.7+ F
*12.7 = 0 ….. E q (5)
z
∑ ML6 = 0
C 1 *114.3 + C2* 63.5+ C 3*12.7 +R1* 12.7 +R3* 63.5+ R 4*38.1 + R5* 63.5 +Fx*38.1+ F y*63.5+ F z*63.5 = 0 ….. E
q (6)
RESULTS AND DISCUSSION
MAT Lab software was used to solve the above equations.
The required Clamping forces are, NB force in newton
position in mm
(C1 =704.26 , C2 =353.42 , C3 =321.78)N when tool at (101.6 , 0,
101.6 )
C1 =678.7 N , C2 =48.6 N , C3 =1324.9 When tool at (101.6 , 0,
76.2 )
C1 =742.4 , C2 =465.2 ,C3 =2436.13 N When tool at (101.6 , 0, 50.8 )
C1 =1002.6 N C2 =548.0 N C3 =1906.6 N at (101.6 mm, 0, 25.4 mm)
The maximum clamping forces among these values are,
C1=1002.6 N C2=548.0 N C3 =2436.1 N
The reaction forces at each locator for these clamping forces are,
R1 = 455.9 , R2 =103.6 ,R3=831.56 , R4 =1484.6 R5 =2057.2
Verification of the calculated clamping forces:
(C2 +C3 +R3 +R4 +R5 +R6)*0.25Fx
(8728.16 *0.25) = 2182.04 >1105.67
In the Y-direction,
(C 1+C 3+R 1+R 2+R4+ R5 +R6 )* 0.25 F y
(8910 * 0.25) = 2227.5 > 442.1
In the Z-direction,
(C1+ C2+ R1+ R2+ R3)* 0.25* Fz
(2941.66 ´ 0.25) = 735.415 >283.56
Thus, the calculated clamping forces are verified by the
coulomb friction law.
Deformation of the work piece using FEM:
Input parameters :-
Load step 5: During load step 5, the material along the tool
path is almost removed. So the deformation of the
workpiece may be increased as that of last two load steps.
This is shown in Fig. 8.5. The deformation of the workpiece
is 0.065876 mm.
From the above five load steps, the maximum deformation
of the workpiece is occurred at the first load step. The
maximum deformation value is 0.149082 mm.
4.0 CONCLUSION
The balancing force-moment method and coulomb
friction law are used to determine the clamping forces.
The clamping forces required to hold the work piece
are calculated for five positions of the machining tool
with respect to work piece
By calculating the optimum clamping forces the
deformation of the work piece may be minimized.
Because of minimum deformation, the dimensional
and form errors of the work piece may be reduced
5.0 SCOPE FOR FUTURE WORK