Intelligent Fixture Design through a Hybrid System of Artificial Neural Network and Genetic Algorithm

In designing fixtures for machining operations, clamping scheme is a complex and highly nonlinear problem that entails the frictional contact between the workpiece and the clamps. Such parameters as contact area, state of contact, clamping force, wear and damage in the contact area and deformation of the component are of special interest. A viable fixture plan must include the optimum values of clamping forces. Along research efforts carried out in this area, this comprehensive problem in fixture design needs further investigation. In this study, a hybrid learning system that uses nonlinear finite element analysis (FEA) with a supportive combination of artificial neural network (ANN) and genetic algorithm (GA) is discussed. A frictional model of workpart–fixture system under cutting and clamping forces is solved through FEA. Training and querying an ANN takes advantage of the results of FEA. The ANN is required to recognize a pattern between the clamping forces and state of contact in the workpiece–fixture system and the workpiece maximum elastic deformation. Using the identified pattern, a GA-based program determines the optimum values for clamping forces that do not cause excessive deformation/stress in the component. The advantage of this work against similar studies is manifestation of exact state of contact between clamp elements and workpart. The results contribute to automation of fixture design task and computer aided process planning (CAPP).     

基于GA和FEM的夹具布局和变夹紧力优化设计

通过夹具布局和夹紧力大小的优化可以提高薄壁件加工精度．建立了夹具布局和变夹紧力分层优化模型．首先,以工件加工变形最小化和变形最均匀化为目标函数,对夹具布局进行优化设计;其次,基于优化的夹具布局对变夹紧力进行设计．采用有限元法计算工件的加工变形,加工变形求解时综合考虑了接触力、摩擦力、切削力、夹紧力和切屑的影响．采用遗传算法求解优化模型,获得优化的夹具布局和变夹紧力．通过实例分析,验证了分层优化设计方法可以进一步减小工件加工变形,提高加工变形均匀度．     

A genetic algorithm based approach to optimal fixture configuration

In this paper the application of genetic algorithms (GAs) to the fixture configuration optimisation problem is presented. A general purpose fixturing verification system has been developed to check the validity of individual fixture configurations by analysing various contact types in the workpiece-fixture system. Based on the information provided by the verification system, a genetic algorithm based approach carries out the evaluation process to determine the most statically stable fixture configuration among a large number of candidates. The preliminary implementation is introduced to demonstrate the ability of GAs and two different coding schemes are tested to explain their influence on the performance of GAs.     

坐标测量机测量点通用可达性分析方法

坐标测量机接触式点位测量必须事先分析测量点的可达性以免测量时发生 碰撞,并给出测量点的可达方向,为测量方向选择提供基础。对于目前常见的各种类型探针, 论文提出了一种通用的测量点可达性分析方法。由用户交互建立任意类型的探针和测头等测 量机部件的简化模型,可达性分析首先根据探针类型快速排除不可达方向,然后通过计算测 量机部件与工件、夹具等障碍物的最小距离精确判断测量点在各个测量方向下的静态可达性 和动态可达性,由此可得到测量点的全部可达方向。在可达性分析中对障碍物进行了离散化 处理,因此,该方法适用于任意复杂程度的零件。     

基于零件特征关注度的夹具实例相似性检索方法

针对传统夹具实例检索方法的不足和三维模型检索的局限性,提出一种对于零件几何形状的零件特征关注度模型表示方法及生成该模型的方法,并给出了根据零件特征关注度模型进行夹具实例检索的算法.根据B-rep实体表示方法构造零件属性邻接图,通过特征提取算法获得零件的特征并计算特征关注度,形成关注度模型.在零件特征关注度模型的基础上,利用非精确图匹配算法匹配零件关注度模型,并应用于夹具设计实例检索过程中.应用证明,该算法可以满足工程应用的需求.     

Stability ofWorkpkce Setup in Feature-Based Fixture Planning System

Analyzed the issues of stability of workpiece during clamping and machining. Discussed classification of the stability problem according to the forces acting on the part in the commonly used machining processes; gave the methods of calculating clamping force and measures to guarantee the stability of workpiece in the feature-based fixture planning design system.     

The integration of modular fixture database, fixturing knowledge base and 3-D fixture planning interface

The objective of this project is to present a computer aided fixturing system (CAFS), which integrates modular fixture database, fixture positions knowledge base and 3-D graphic display interface. The system will automatically select and layout the fixture elements to secure a workpiece through an interactive progress. This work can be sub-divided into three tasks. The first task is to build a modular fixture element database. The second task is to determine true positions of modular fixture elements given a set of fixture points, called fixture configuration. The third task is to provide a 3-D graphic interface to display and refine the fixture plan interactively. The system will be developed on the platform of a solid modeler, I-DEAS. Using this platform, the user can graphically rearrange fixture elements to refine the fixture plan.     

An integrated methodology for fixture design

In this paper, a methodology to perform fixture design as an integrated aspect of process planning is proposed. A three-phase methodology for the fixture design activity has been developed. The three phases include predesign analysis (phase I), functional analysis (phase II), and productivity improvement (phase III). In phase I, the product design information is studied, and initial fixture design aspects are developed. In phase II, the clamping and location aspects of fixture design are addressed for the given initial process sequence and product design information. Phase III involves studying ways to increase the productivity including using simultaneous machining approaches, multiclustering, use of specialized jigs, etc.     

Analysis and optimization of fixture under dynamic machining condition with chip removal effect

Dynamic interactions in the tool–workpiece and workpiece–fixture systems significantly impinge on the quality of finished workpieces. The presented simulation system integrates the effects of workpiece fixture dynamics with the other factors contributing to the machining process dynamics. It provides more accurate prediction of the process output which helps in the design of the optimum fixture configuration prior to the production stage. Modelling of the frictional contact behaviour between the fixture element and the workpiece helps to improve the prediction accuracy of the simulation system which accelerates the convergence to the optimum fixture configuration design and consequently improves the machined part dimensional accuracy and geometric integrity. The developed simulation is capable of modelling complicated part geometries by interfacing with commercial ANSYS.V10^® packages. This research work minimizes the deformation of workpiece using integrated optimization tool of Genetic algorithm (GA) and ANSYS Parametric Design Language (APDL) of finite element analysis. The same layouts given by the above optimization tool are used in the experimental setup and it is found that the improved geometric tolerance of squarness and flatness of the given workpiece. The chip removal effect and frictional contact between the workpiece and the fixture elements are taken into account based on element death technique and nonlinear finite-element analysis. A Case study of an open slot milling process illustrates the application of the proposed improved geometric tolerance approach.     

Multi-Objective Approach to Automated Fixture Synthesis Incorporating Deep Neural Network for Deformation Evaluation

In machining, the synthesis of a fixturing schema significantly impacts the accuracy of the final product. Moreover, A robust and automatic configuration of fixture elements can reduce production costs and eliminate the need for expert labor to perform the task. Given the multi-modal problem of fixture synthesis, this article presents a multi-objective approach to fixture synthesis in the discrete domain. The performance criteria are localization accuracy, detachment of locators, workpiece deformation, severity and dispersion of reaction loads, and the spacing between contact points. Optimization is performed via an improved Declining Neighborhood Simulated Annealing algorithm (DNSA). To achieve consistent performance over different inputs, the number of iterations follows a Shanon entropy index reflecting the recurrence of folds/corners. Except for deformation, all other objectives are derived from the kinematic analysis of the workpiece-fixtures system. In contrast, deformation is estimated via a Constitutive Deep Neural Network (CDNN). Both models incorporate the machining loads as quasi-static intervals. A new strategy is adopted for the trade-off based on the Z-score quantification of objectives through a pre-calibration run of DNSA. Numerical examples demonstrate the implementation flow of our generalized CAD-based tool developed for the purpose. The approach is verified and proved efficient in automating the robust selection of a fixture layout for a prismatic workpiece.     

Automated modular fixture planning: Accuracy, clamping, and accessibility analyses

Attendant Processes such as fixture and die design are often a necessary but time-consuming and expensive component of a production cycle. Coupling such attendant processes to product design via feature-based CAD will lead to more responsive and affordable product design and redesign. In the context of on-going research in automating fixture configuration design, this paper presents a fundamental study of automated fixture planning with a focus on geometric analysis. The initial conditions for modular fixture assembly are established together with geometric relationships between fixture components and the workpiece to be analyzed. Of particular focus is the design of alternative locating points and components, together with examples of 3-D fixture designs.     

Multi-objective optimal fixture layout design

This paper addresses a major issue in fixture layout design to determine and evaluate the acceptable fixture designs based on multiple quality criteria and to select an optimal fixture with appropriate trade-offs among multiple performance requirements. The performance objectives considered are related to the fundamental requirements of kinematic localization and total fixturing (form-closure). Three performance objectives are defined as the workpiece localization accuracy and the norm and dispersion of the locator contact forces. The paper focuses on multi-criteria optimal design with a hierarchical approach. An efficient interchange algorithm is extended and used for different practical cases, leading to proper trade-off strategies for performing fixture synthesis. Examples are given to illustrate empirical observations with respect to the proposed approach and its effectiveness.     

The stencil buffer sweep plane algorithm for 5-axis CNC tool path verification

A new algorithm based on the sweep plane approach to determine the machined part geometry in 5-axis machining with general APT tools is presented. Undercut and overcut can be determined. Collision detection between the toolholder, workpiece and workpiece fixture can also be detected. The subtraction of the removed material is obtained for each sweep plane by using a stencil buffer. A flat plane is swept through the blank part, fixture and tool swept volume geometry. The intersections of sweep planes and the swept tool volume are computed based on the canonical representation of a cone, torus and sphere. The necessary data to compute all the intersections is stored in a text file, here called the M-Plane file (Memory Plane). The equations of the intersections are approximated by a polygon with variable accuracy. The resulting APT tool intersection in each sweep plane is then clipped against the blank workpiece intersection with the current sweep plane. The stencil buffer provides automatically the union of all tool intersections and the subtraction from the blank workpiece. This algorithm provides a 3D geometric model of the tool swept volume. The display algorithm is based on the Painter's algorithm, but there is no time consuming sorting from back to front required, as the sweep proceeds from back to front. The accuracy of the algorithm can be varied as a function of the requirements by changing the polygon approximation and the distance between the sweep planes.     

A desktop virtual reality-based interactive modular fixture configuration design system

Modular fixture configuration design is a complicated task requiring strong professional background and practical experience. However, automated or semi-automated computer aided modular fixture systems based on CAD packages still are not well accepted by the manufacturing industry due to the lack of intuitive interaction and immediate feedback compared with traditional models such as paper and physical models. In this paper, a novel Virtual Reality-based system for interactive modular fixture configuration design is presented. We use a multi-view based modular fixture assembly model to assist information representation and management. In addition, the suggested strategy is compatible with the principles of virtual environment and it is easy to reutilize the element model. Based on geometric constraints, we propose a precise 3D manipulation approach to improve intuitive interaction and accurate 3D positioning of fixture components in virtual space. Thus, the modular fixture configuration design task can precisely be performed in virtual space.     

An integrated fixture planning and analysis system for machining processes

Fixture planning is an important part of computer-aided process planning (CAPP), which is the link between design and manufacturing in a CIM environment. This paper presents a rational approach to computer-assisted fixture planning (CAFP), emphasizing integration of fixture planning with process planning, an issue that has not been adequately addressed until very recently. A systematic approach to fixture selection is outlined for planning of modular fixtures. A prototype CAPP-CAFP system has been developed at UCLA and linked to a commercial CAD system, namely, CADAM. Part design information can be extracted from the CAD model and multiple-view engineering drawings of a part stored in the CADAM system. Modular fixture elements can be selected automatically by the CAPP-CAFP system and the generated fixture layout can be displayed on the screen. Included also in the system is a fixture analysis module for verification and rationalization of a fixturing scheme. The force analysis module has a built-in local optimization routine that can determine the clamping forces of more reasonable magnitudes. The friction forces between the fixture and the workpiece can also be considered for simple cases.     

车载超短波电台维修检测系统的设计与实现

针对某新型车载超短波电台原理结构复杂、自检虚警率高、故障定位困难等问题,综合采用嵌入式技术、数据库软件、电路智能检测等技术,以车载超短波电台维修检测主机+模件测试夹具的架构构建硬件平台,研制开发车载超短波电台维修检测系统;该系统能够实现对车载超短波电台整机频率误差、输出功率、接收灵敏度等参数及电台内部模件性能指标的自动化测试,测试结果与标准特征值比对,实现电台整机技术状态评估和模件级故障定位,实现电台维修信息的实时存储与查询,从而解决陆军部队车载超短波电台维修检测手段不足、维修保障困难等实际问题。     

Dimensional synthesis of a robotized cell of support fixture

In this paper, an optimal designed 8-SPU parallel mechanism, acting as a cell of the self-configurable fixture which is used to support and clamp the thin-walled, large-scale plate and shell workpiece in automotive, aircraft and ship manufacturing industries, is proposed. In order to locate the maximum workspace with the global dexterity and conformity dexterity, single and multiple objective optimizations are performed under conditions of geometric constraints and kinematic performance indices by particle swarm optimization. The structural comprehensive parameters of parallel mechanism, such as the layout of joint points on the upper platform, the angle between two limbs of leg, and the ratio of radii of fixed to moving platforms, are optimized to obtain the optimal design dimensions. Furthermore, the effect of the optimized variables on kinematic performance indices is also intensively investigated. The compared results of the two optimization approaches indicate the feasibility of the proposed procedures.     

Applying RBR and CBR to develop a VR based integrated system for machining fixture design

A fixture is a special tool used to accurately and stably locate the workpiece during machining process. Proper fixture design improves the quality and production of parts and also facilitates the interchangeability of parts that is prevalent in much of modern manufacturing. This study combines the rule-based reasoning (RBR) and case-based reasoning (CBR) method for machining fixture design in a VR based integrated system. In this paper, an approach combines the RBR and fuzzy comprehensive judgment method is proposed for reasoning suitable locating schemes and locating features. Based on the reasoning results, a CBR method for machining fixture design is then presented. This method could help designers, by referencing previous design cases, to make a conceptual fixturing solution quickly. Finally, the implementation of proposed system is outlined and cases study has been used to demonstrate the applicability of the proposed approach.     

The application of neural networks in fixture planning by pattern classification

The objective of this paper is to study the fixture planning of modular fixtures for cutting by means of a computer-aided fixture system (CAFS). The fixture planning presented here integrates the database of modular fixtures, neural networks, the heuristic algorithm of fixture position and the use of Advanced Modelling Extension Release 2.1 (AME) of AutoCAD R12 as the 3D graphic interface. The function suitable for the AME environment was also controlled to obtain detailed data of the geometry and topology of the workpiece to develop the fixture planning for modular fixtures. First of all, the concept of group technology (GT) was used to establish the coding database of the modular fixture element for use in the system. This paper presents fixture planning which combines the pattern recognition capability of the neural networks and the concept of GT to group the workpieces with different patterns but identical fixture modes into the same group. After network training, the fixture mode of the workpiece to be clamped can be inferred, and the selection of the fixture elements can be completed.     

Locating completeness evaluation and revision in fixture plan

Geometry constraint is one of the most important considerations in fixture design. Analytical formulation of deterministic location has been well developed. However, how to analyze and revise a non-deterministic locating scheme during the process of actual fixture design practice has not been thoroughly studied. In this paper, a methodology to characterize fixturing system's geometry constraint status with focus on under-constraint is proposed. An under-constraint status, if it exists, can be recognized with given locating scheme. All un-constrained motions of a workpiece in an under-constraint status can be automatically identified. This assists the designer to improve deficit locating scheme and provides guidelines for revision to eventually achieve deterministic locating.