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TECHNICAL PAPERS

Systematic Modeling of Workpiece-Fixture Geometric Default and Compliance for the Prediction of Workpiece Machining Error

[+] Author and Article Information
Guohua Qin

Sino-French Laboratory of Concurrent Engineering, School of Mechatronic Engineering, Northwestern Polytechnical University, P. O. Box 552, 710072 Xi’an, Shannxi, China; Department of Mechanical Engineering, Nanchang Institute of Aeronautical Technology, P. O. Box 61, 330034 Nanchang, Jiangxi, China

Weihong Zhang1

Sino-French Laboratory of Concurrent Engineering, School of Mechatronic Engineering, Northwestern Polytechnical University, P. O. Box 552, 710072 Xi’an, Shannxi, Chinazhangwh@nwpu.edu.cn

Zhuxi Wu

Department of Mechanical Engineering, Nanchang Institute of Aeronautical Technology, P. O. Box 61, 330034 Nanchang, Jiangxi, China

Min Wan

Sino-French Laboratory of Concurrent Engineering, School of Mechatronic Engineering, Northwestern Polytechnical University, P. O. Box 552, 710072 Xi’an, Shannxi, China

1

Author to whom correspondence should be addressed.

J. Manuf. Sci. Eng 129(4), 789-801 (May 03, 2006) (13 pages) doi:10.1115/1.2336260 History: Received November 20, 2005; Revised May 03, 2006

Control of workpiece machining error (WME) is a key concern in the design of a fixture system. In this paper, source errors, which are categorized into workpiece-fixture geometric default and workpiece-fixture compliance, are systematically investigated to reveal their effects upon the WME. The underlying mechanism is that source errors lead to the workpiece position error (WPE), the workpiece elastic deformations (WED), and the inconsistent datum error (IDE), and all of them will contribute together to the WME. Here, the IDE refers to the dimension deviation of the processing datum from the locating datum once two references do not coincide. An overall quantitative formulation is proposed for the computing of WME in terms of WPE, WED, and IDE for the first time. In detail, the WPE raised in the workpiece-locating and clamping process is evaluated based on the geometric defaults and local deformations of workpiece-fixture in the contact region. The WED relative to the workpiece-clamping process is determined by solving a nonlinear mathematical programming problem of minimizing the total complementary energy of the frictional workpiece-fixture system. Some numerical tests are finally demonstrated to validate the proposed approach on the basis of both theoretical and experimental data given in the references.

Copyright © 2007 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Illustration of the workpiece-fixture system

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Figure 2

Source errors due to geometric default

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Figure 16

FE results for Tan’s model (29)

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Figure 3

Source errors due to workpiece-fixture compliance

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Figure 5

Workpiece-fixture system

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Figure 6

Machining error relative to geometric default

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Figure 7

Machining error of angular dimension

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Figure 8

Computing procedure of the overall machining error

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Figure 9

V-block locating scheme

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Figure 18

Workpiece deformations

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Figure 10

A workpiece-fixture system

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Figure 11

Scheme of 3-2-1 fixture setup

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Figure 12

Prediction results of contact forces

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Figure 13

Prediction results of the workpiece position error

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Figure 14

Experimental setup

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Figure 15

Measured contact forces in Tao’s experiment (28)

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Figure 19

Radius deformations of hole 1

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