Optimization Method of Floating Fixture Layout for Distortion Control of Low-Stiffness Thin-Walled Beams.

Area of Science:

• Manufacturing Engineering
• Mechanical Engineering
• Materials Science

Background:

• Low-stiffness thin-walled beams are prone to significant elastic deformation during machining.
• The floating fixture method is commonly used but can lead to substantial deformation.
• Minimizing this elastic deformation is crucial for achieving high-precision components.

Purpose of the Study:

• To develop an optimized floating fixture layout method for reducing elastic deformation in low-stiffness thin-walled beams.
• To establish a calculation model for elastic deformation and define an objective function for maximum total elastic deformation.
• To validate the proposed optimization method through theoretical calculations, simulations, and experimental measurements.

Main Methods:

• Optimization of the number and position of fixture points.
• Development of an elastic deformation calculation model and an objective function for maximum total elastic deformation.
• Application of the augmented multiplier method for optimized solutions.
• Experimental validation using an aluminum alloy low-stiffness thin-walled beam.

Main Results:

• The optimized fixture layout reduced simulated maximum elastic deformation by 48.49%.
• Experimental measurements showed an average reduction in deformation of 0.02 mm, a 74.07% decrease.
• The average relative error between calculated and simulated total maximum elastic deformation was 17.43%.

Conclusions:

• The proposed floating fixture layout optimization method is effective in controlling and reducing machining elastic deformation.
• The method significantly enhances the precision of manufacturing processes for low-stiffness thin-walled components.
• Optimized fixture design is a critical factor in mitigating elastic deformation in precision manufacturing.