氣門搖臂軸支座的加工工藝分析及其夾具設(shè)計【銑36mm端面】【鉆φ18孔】【說明書+CAD】,銑36mm端面,鉆φ18孔,說明書+CAD,氣門搖臂軸支座的加工工藝分析及其夾具設(shè)計【銑36mm端面】【鉆φ18孔】【說明書+CAD】,氣門,搖臂,支座,加工,工藝,分析,及其,夾具,設(shè)計,36,mm 2212-8271 2013 The Authors. Published by Elsevier B.V.Selection and peer-review under responsibility of Professor Pedro Filipe do Carmo Cunhadoi: 10.1016/j.procir.2013.05.039 Procedia CIRP 7 ( 2013 ) 228 233 Forty Sixth CIRP Conference on Manufacturing Systems 2013 Fixture and Setup Planning and Fixture Configuration System Rtfalvi Attila a*, Michael Stampfer.b, Szegh Imre cSubotica Tech, Marka Orekovi a 16, 24000 Subotica, Serbia Unuversity of Pcs ,Rkus u.2 , 7625 Pcs, Hungary Budapest University of Technology and Economics, Egri Jzsef u. 1, H-1111 Budapest, Hungary * Corresponding author. Tel.: +381-24-655-222; fax: +381-24-655-255,.E-mail address: ratoszvts.su.ac.rs Abstract By automating the tasks of the fixture design and configuration we can save considerable time, and spare the process engineer from a tiresome work. In this paper a system is introduced that gives us recommendations on the number and the order of the needed setups, and proposals on the appropriate fixtures needed at machining a given workpiece. The input data are the CAD model of the workpiece saved in IGES format, and the technological requirements. The output data are the CAD models of the needed fixtures. 2013. Rtfalvi A., Stampfer M., Szegh I. Published by Elsevier B.V. Selection and/or peer-review under responsibility of Professor Pedro Filipe do Carmo Cunha Keywords: fixture planning; fixture design 1. Introduction Fixtures help us to increase the productivity and the precision of the workpiece. The productivity is increased through decreasing the time needed for taking off the finished workpiece, and setting up the new one, and through increasing the cutting parameters due to stable supporting and clamping of the workpiece. Increased precision can be achieved with the help of precise locating and stable supporting and proper clamping of the workpiece. From these requirements follows that we have to carefully select the datum surfaces on the workpiece for supporting, locating and clamping, and then have to carefully choose out the functional fixture elements, and find for them such layout, which will ensure unhindered motion of the tools. Of course to reduce the stand time we also must keep the number of setups as low as possible. Often, to find an acceptable layout, we have to work out several datum surface combinations, and for each a fixture element layout while we find an acceptable solution. This is a tiresome and time-consuming process, and in order to speed up this process we have developed a system that gives proposals on the needed setups and can build a fixture for any accepted proposal. The built fixtures can be visualized in Solid Edge environment, and can be easily changed if eventually something should be changed. Since a system that is capable to give solution for any workpiece machine tool combination would be enormous; our work is confined on box-shaped parts (first of all gearbox houses) that are machined on horizontal machining centers. 2. Literature overview Since it is an ancient desire of the process engineers to make somehow quicker and easier the setup and fixture planning and the fixture design, there were numerous attempts to algorithm these tasks. Some attempts focused on setup automation; others on fixture planning Kulankara and Melkote1, Necmetin2, Wang et al.3; some on fixture design Gaoliang et al.4, Shasha et al.5, Zhou et al.6; and of course there were attempts to solve all these tasks within one system. Farhan and Tolouei7 developed a Solid Works based fixture planning and design system. These are only a few of the most recent results. Available online at 2013 The Authors. Published by Elsevier B.V.Selection and peer-review under responsibility of Professor Pedro Filipe do Carmo CunhaOpen access under CC BY-NC-ND license.Open access under CC BY-NC-ND license.229 Rtfalvi Attila et al. / Procedia CIRP 7 ( 2013 ) 228 233 3. Systematization of the main fixturing tasks in case of box-shaped parts Due to the great variety in shape, size and material of the workpieces it would take a huge system to classify all the workpiece types and the best fixture types for each, but the subtask like supporting, locating and clamping can be typed. In Fig. 1 the different supporting (primary locating) types on horizontal machining center are shown. Fig. 1. Supporting types In case of pos1 four sides of the workpiece can be machined in one setup, in case of pos2 three sides, in case of pos3 three sides plus the fourth side partly - through the openings on supporting side. Fig. 2 presents the different guiding (secondary locating) and end stopping (tertiary locating) types. Fig. 2. Side locating types There are 4 types of side locating (guiding) established (fig.2): (1) side locating with the help of surfaces adjoining to the supporting face, (2) side locating with the use of two inside diameters on the supporting face, (3) side locating with utilization of one inside diameter laying on the supporting face and one face adjacent to the supporting face, (4) side locating with application of two threaded joints (with fitted shaft screws) on the supporting face. In Fig. 3 one can see the different types of clamping most commonly used for box-shaped parts. Based on the clamping force direction one can distinguish (fig.3) perpendicular clamping (s1) the clamping force is perpendicular to the supporting surface - and parallel clamping (s2) the clamping force is parallel with the supporting surface. Fig. 3. Clamping types The basic type s1, depending on location of the clamping faces, can be further divided into subtypes s11, s12 and s13. In the case of s11 the clamping surfaces are the closest parallel faces to the plane-locating (supporting) surface. In the case of s12 the clamping surface(s) is on the opposite side of the plane locating face. By s13 the clamping is carried out using a trough hole on the workpiece. One special way of clamping is clamping by screws and threaded joints on the plane locating face (s3). In this case the clamping forces are acting perpendicular, but the force transmission happens in different way. The number of clamping points is also a very important characteristic of a clamping. We distinguish clamping in one, two, three or four points. If we supplement the previous basic types with this information, the possible clamping types are obtained: s11_2, s11_3, s11_4; s12_2, s12_3, s12_4; s13_1, s13_2; s2_1, s2_2; s3_2, s3_3, s3_4. In the enumerated notation the last number means the number of clamping points. 4. The structure of the system The planned system consists of four modules: 1) The CAD model post processing/fixture pre processing module (IPPO) which analyzes the curves and surfaces on the CAD model of the workpiece, extracts their most important characteristics, and organize them into technological and fixturing features. 2) The setup and fixture planning module (SUPFIX) which, on the base of the output data of the previous module, gives proposal on the number and order of the needed setups, and proposal on the conceptual solution of the needed fixture(s). 230 Rtfalvi Attila et al. / Procedia CIRP 7 ( 2013 ) 228 233 3) The operation-planning module (OP) this module is not constructed yet. The role of this module will be to decompose the setups onto particular cuts, to select concrete tools for each cut, and to determine the cutting parameters for each cut. 4) The fixture configuration module (FIXCO) for the accepted conceptual solutions tries to build concrete fixture assemblies. These assemblies with the help of a little VB program (GLUE) can be opened in Solid Edge assembly environment; where interference check can be done, and - if necessary even further changes can be made. The fixture documentation in the possession of these can be easily and quickly made. The CAD model of the assembled fixture can be opened with a CAM program, and there the fixture elements can be marked as check bodies, and this way such tool paths generated, where the tool does not collide with fixture elements. In Fig. 4 one can see the schematic view of the system. Fig. 4. The setup and fixture planning and fixture design system 4.1. The CAD model post-processing module This module analyzes all the curves and surfaces of the workpiece model, and tries to organize them into features, and extracts the characteristic data of the assumed feature. The types of the features the module can recognize are shown in Fig. 5, these are different kind of holes (blind or through holes with or without thread, with or without sinkage, with or without slots), different raised (boss top) surfaces, different sinked (pocket bottom) surfaces, group of surfaces laying on the same “height”. Fig. 5. The most common features on gearboxes 231 Rtfalvi Attila et al. / Procedia CIRP 7 ( 2013 ) 228 233 Such surface groups (tf5 03) can further be divided into subgroups depending on the global form they are forming, and on the number of the members of the group (Fig. 6). Fig. 6. Subgroups of the surface groups Of course the sort of recognized features can be further increased - if necessary by adding new rules to the system. The characteristic data of the features or surfaces (dimensioned in the figures) are automatically extracted from the model. These data are important first of all from the technological aspect, but some of them from fixturing aspect too. The features and surfaces are classified on the basis of their shape, size and location. For example too small surfaces, or surfaces with a shape that certainly can not be used neither for supporting, nor for guiding, end stopping or clamping are eliminated in order to reduce the time needed for the next module to find an acceptable solution. The workflow looks like this, the user (process engineer) opens the CAD model of the workpiece saved in IGES format, and checks the recognized features, prescribes which features or surfaces has to be machined, with what precision, then prescribes the relationship tolerances, and finally saves the data. A more detailed description about this module can be read in 8. 4.2. The setup and fixture planning module The user opens with this module the saved file containing the output data of the previous module, and visually checks the modules proposals on the conceptual solution of the fixture for the main setup, and if likes it the user can accept it. After that the user visually checks the modules proposals on the conceptual solution for the auxiliary setup(s), and can accept or refuse it. If a conceptual solution is refused, the module searches for another conceptual solution. At first the module gives proposals for the main setup (where the most important tolerances are machined), proposal on the type of the supporting, and on the surface(s) to be used for supporting, proposal on the type of the locating, and on the surface(s) to be used for locating, and proposal on the type of the clamping, and the surface(s) to be used for clamping. First, it tries to find such orientation for the workpiece in which all tolerance connected sides of the workpiece can be machined in the same setup this is the technologically ideal orientation. If this does not succeed, then it tries to find such orientation where all strictly connected sides can be machined in the same setup (loose tolerances are left out from consideration). If this attempt brings no success either, then it tries to find such orientation where at least all strictly connected features (surfaces) can be machined in the same setup. If none of the mentioned strategies bring fruit, then one must machine some strictly connected tolerances in different setups (what means that complicated and expensive features have to be used). The size and shape of the supporting surface candidates are examined; firstly big enough flat surfaces are taken in consideration, secondly big enough cylindrical, thirdly big enough groups of flat surfaces. Apart from size and shape, the locating surface candidates are also investigated from the aspect of location, too. The clamping surface candidates are also examined from the aspects of size, shape and location, and except that from the aspect of possible force closing direction, since it is the best when the greatest cutting force is in form closed way hindered. This module is more detailed introduced in 9. 4.3. The fixture configuration module The user opens one of the output files (either the one that contains the conceptual solution for the main, or the one that contains the conceptual solution for the auxiliary setup) generated by the previous module, and this module tries to build an acceptable fixture. The built fixture applies the supporting method proposed in the conceptual solution, on the surface(s) recommended for supporting, selects the type and the size of the supporting elements, and puts them on appropriate 232 Rtfalvi Attila et al. / Procedia CIRP 7 ( 2013 ) 228 233 position relative to the workpiece, which is rotated to work position. Also it selects the type and the size of the locating elements in accordance with the proposed type of locating (this way the search place is significantly reduced, so the fixture building time is cut down). The selected locating elements are put in the appropriate position relative to the workpiece. Finally, it selects the clamping elements, which are eligible for the proposed clamping type, defines their size so that the contact area between the workpiece and the clamping element is large enough. The gridhole in which the clamping element is directly mounted, or with the help of some adapting elements, must be as close to the clamping place as it is possible, in order to minimize the moment acting on the clamping element. Adopting elements are not always used, only in cases when the clamping or locating surface is too far (for example, too high) from the closest grid hole on the base plate. The number of adapting elements must be minimized, thus the precision and the rigidity of the fixture is greater. 5. Results of a test run In Fig. 7 a typical box-shaped part is presented, a gearbox housing cast in sand from gray cast iron. The most important tolerances are dimensioned on the part, for better understanding one piece is broken out. Fig. 7. Gearbox housing In Fig. 8 the surfaces machined during the first setup are marked (the bottom, and the four through holes on it), in Fig. 9 the surfaces machined during the second setup are marked. In Fig. 10 the proposed conceptual solution for the first (auxiliary) setup is presented. On the basis of the proposal, the workpiece during the first setup (where the datum surfaces of the second setup are machined) should be laid on the violet ring-like surface (the proposed supporting type is pos1), should be positioned over the four red inner cylindrical surfaces and the gray (black) flat angled surface (the proposed locating type is p3). The clamping should be executed on the green ring-like surface (the proposed clamping type Fig. 8 Surfis s13). aces machined during the first setup The fixture built by the FIXCO module on the basis ofroposed conceptual solution for the sea screw is put to bridge the missing distance. Fig. 9 Surfaces machined during second setup these recommendations can be seen in Fig. 11, where the fixture together with the workpiece is shown. In Fig. 12 the same fixture is presented without the workpiece. The workpiece is laid on the three gold colored adjustable supports, located with the help of three blue straight bolts (centering) and the adjustable stop (direction), clamped with the help of a strud and an open strap (the nut is not put) over a through hole. Since the strud is not long enough, an adapter element is needed too, a tie-rod bolt. In Fig. 13 the pcond (main) setup is shown. The workpiece should be laid on the violet flat surfaces (the proposed supporting type is pos1), should be located over the black and red through holes (the proposed locating type is p22), and should be clamped over the four green flat surfaces (s11 type clamping is proposed). In Fig. 14 the built fixture can be seen together with the workpiece, in Fig. 15 the built fixture without the workpiece can be seen. For supporting a special base plate is used without gridholes. The holes for locating pins are machined on the appropriate place depending on the workpiece. The locating elements are the two gold colored straight bolts. Four hook clamps are selected for fulfilling the clamping task, and (since their adjustability is not enough) in each 233 Rtfalvi Attila et al. / Procedia CIRP 7 ( 2013 ) 228 233 Rtfalvi A., Stampfer M., Szegh I./ Procedia CIRP 46th (2013) 000000 Fig. 10. The proposed conceptual solution for the first (auxiliary) setup Fig. 11. The built fixture for the first setup with the workpiece Fig. 12. The built fixture for first setup wihtout the workpiece Fig. 13. The proposed conceptual solution for the second (main) setup Fig. 15. The built fixture for the second setup without the workpiece 6. Conclusion In this paper a fixture planning and design system is presented, which makes the work of the process engineer easier and quicker. The system was tested for several industrial parts, and gave good results (in view of the accuracy, the possible simplest structure of the fixture and enough stability). When the operation planning module of the system will be developed, in the possession of the dimensions of the concrete cutting tools, the built fixture can be verified from the aspect of the tool approach, too. 15 Shasha Z., Xiaojin W., Wenlong L., Zhouping Y., Youlun X., A novel approach to fixture design on suppressing achining flexible workpiece, International Journal of Machine Tools & Manufacture 2012:58:2943 g 2011:27:9867 3D-modelling approach”, 19 International 8 t processing Manufacturing Technology 2009:45:540552 References Kulankara K., Shreyes N. M., Machining fixture layout optimization using the genetic Algorithm, International. Journal of Machine Tools & Manufacture 2000:40:579598 2 Necmettin K., Machining fixture locating and clamping position optimization using genetic algorithms, Computers in Industry 2006:57:112120 3 Y. Wang_, X. Chen, Q. Liu, N. Gindy , Optimisation of achining fixture layout under multi-constraints , International Journal of Machine Tools & Manufacture 2006:46:12911300 4 Gaoliang P., Guangfeng C., Chong W., Hou X., Yang J., Applying RBR and CBR to develop a VR based integrated system for machining fixture design, Expert Systems with Applications 2011:38:2638 vibration of6 Yunbo Z., Yingguang L., Wei W., Feature-based fixture design methodology for the manufacturing of aircraft structural parts, Robotics and Computer-Integrated Manufacturin993 U. Farhana and M. Tolouei-Rada, 2011. “Design of modular fixtures using a thCongress on Modelling and Simulation, Perth, Australia, 1216 December 2011 Rtfalvi A., 2011. “IGES-based CAD model posmodule of a Setup and Fixture Planning System for boxshaped parts”, SISY 2011, IEEE 9th International Symposium on Intelligent Systems and Informatics, Subotica, Serbia, Sept. 8-10, 2011 9 M. Stampfer, Automated setup and fixture planning system for box-shaped parts, International Journal of Advanced Fig. 14. The built fixture for the second setup with the workpiece