Intelligent Fixtures for the Manufacturing of Low Rigidity Components (eBook)

Hans Christian Moehring, Petra Wiederkehr, Oscar Gonzalo, Petr Kolar (Autoren)

eBook Download: PDF

2017 | 1st ed. 2018
XXX, 183 Seiten
Springer International Publishing (Verlag)
978-3-319-45291-3 (ISBN)

Infos

The book summarizes the results of the European research project 'Intelligent fixtures for the manufacturing of low rigidity components' (INTEFIX). The structure of the book follows the sub-projects which are dedicated to case studies within the scenarios 'vibrations', 'deformations' and 'positioning'. The INTEFIX project deals with the development and analysis of several exemplary types of intelligent, sensor and actuator integrated fixtures for the clamping of sensitive workpieces in cutting machine tools. Thus, the book gives a representative overview about this innovative field of technology. The demands of the case studies are described and the technological approaches and solutions are introduced. Furthermore, innovative methods for the design and optimization of intelligent fixtures are presented.

Inhalt

Preface 6
Acknowledgements 8
Contents 9
Abbreviations 14
Introduction 16
Methodology 18
Vibration 30
1 Case Study 1.1: Identification and Active Damping of Critical Workpiece Vibrations in Milling of Thin Walled Workpieces 31
Abstract 31
1.1 Introduction of the Case Study 32
1.2 Stability of Impeller Blade Machining Operations 34
1.3 Single Degree of Freedom Test Rig 37
1.4 Simulation of the Influence of a Counter Excitation 39
1.5 Preliminary Prototype of Rotational Intelligent Chuck 41
1.6 Sensor Integrated CFRP Structures 43
1.7 Experimental Results 46
1.8 Summary and Conclusion 50
References 50
2 Case Study 1.2: Turning of Low Pressure Turbine Casing 52
Abstract 52
2.1 Introduction of the Case Study 53
2.2 Analysis of the Fixture and Workpiece 54
2.3 Fixture Development 56
2.4 Verification and Validation Tests 60
2.4.1 Verification tests 60
2.4.2 Validation tests 63
2.5 Summary and Conclusion 64
References 65
3 Case Study 1.3: Auto-adaptive Vibrations and Instabilities Suppression in General Milling Operations 66
Abstract 66
3.1 Introduction of the Case Study 67
3.2 Active Fixture Development 68
3.2.1 Fixture Architecture and Mechanical Design 68
3.2.2 Actuators Selection and Implementation 70
3.3 Control Logic Development/Implementation 72
3.3.1 Frequency Analysis and Excitation 73
3.3.2 ANN Model and Simulation 74
3.3.3 GA Controller 74
3.3.4 Synthesis 76
3.4 Validation Results 76
3.4.1 Equipment and Test-Case 76
3.4.2 Tests Description and Performance Assessment 77
3.4.3 Results 78
3.5 Summary and Conclusion 80
References 81
Deformation 83
4 Case Study 2.1: Detection and Compensation of Workpiece Distortions During Machining of Slender and Thin-Walled Aerospace Parts 84
Abstract 84
4.1 Introduction of the Case Study 85
4.2 Principle Approach 86
4.3 Fixture Frame Test Rigs 87
4.4 Sensor and Actuator Integration Concept 92
4.5 Adaption of NC-Milling Paths 95
4.6 Prototype of the Intelligent Fixture 97
4.7 Process-Simulation Integrated Machining Operations 99
4.8 Process Simulation of the Final Prototype 100
4.9 Summary and Conclusion 102
References 103
5 Case Study 2.2: Clamping of Thin-Walled Curved Workpieces 105
Abstract 105
5.1 Introduction of the Case Study 106
5.2 Demonstration Workpiece 107
5.3 Introduction of the Fixture Unit 109
5.4 Thickness Sensor 113
5.5 Operator Software 114
5.6 Communication Concept and Complete Fixture System Description 114
5.7 Tool Selection and Cutting Condition Optimization 115
5.8 Overall Machining Strategy 118
5.9 Case Study Results 120
5.10 Case Study Summary 121
5.11 Conclusions 122
References 122
6 Case Study 2.3: Distortions in Aeronautical Structural Parts 123
Abstract 123
6.1 Introduction of the Case Study 124
6.2 First Fixture Design 126
6.2.1 Conceptual Requirements for Fixture 1 126
6.2.2 Requirement Realization for Fixture 1 127
6.3 Second Fixture Design 132
6.3.1 Conceptual Requirements for Fixture 2 132
6.3.2 Requirement Realization for Fixture 2 132
6.4 Results 133
6.4.1 Evaluation of the Stock Residual Stress Characterization and Part Distortion Modules 133
6.4.2 Application of the Developed Methodology to the Test Part 135
6.5 Summary and Conclusion 137
References 138
7 Case Study 2.4: Machining of Aircraft Turbine Support Structures 140
Abstract 140
7.1 Introduction of the Case Study 141
7.2 Fixture Development 143
7.3 Verification and Validation Tests 148
7.3.1 Verification tests 148
7.3.2 Validation tests 150
7.4 Summary and Conclusion 154
Positioning 156
8 Case Study 3.1: Fixture System for Workpiece Adjustment and Clamping with/without its Pre-deformation 157
Abstract 157
8.1 Introduction of the Case Study 158
8.2 Developed Solution Overview 159
8.3 Fixture Design 161
8.3.1 Static Fixture—Leveling Unit 161
8.3.2 Static Fixture—Clamping Unit 162
8.3.3 Dynamic Fixture 163
8.3.4 Static Fixture for Clamping with Pre-deformation 164
8.4 System Integration 165
8.5 Validation under Real Conditions 168
8.6 Summary and Conclusion 171
Reference 171
9 Case Study 3.2: Semiautomatic Tool Reference for Application on Large Parts 172
Abstract 172
9.1 Introduction of the Case Study 173
9.2 Photogrammetry System 176
9.2.1 Software for Minimisation of Material to be Removed 177
9.2.2 On-machine Photogrammetric Process for Measurement of the Misalignment between the Part and the Machine Axes 177
9.3 3-DoF Alignment Table Design and Fabrication 179
9.4 3-DoF Alignment Table Control 182
9.5 Verification and Validation 182
9.6 Summary and Conclusion 185
References 186
10 Case Study 3.3: Active Fixtures for High Precision Positioning of Large Parts for the Windmill Sector 187
Abstract 187
10.1 Introduction of the Case Study 188
10.2 Clamping Technologies 188
10.3 General Overview of Requirements for Active Fixture Design Approach 189
10.4 Detailed Description of the Proposed Fixturing Solution 191
10.4.1 Clamping Technology 191
10.4.2 Designed Lateral Linear Feed-Drive 192
10.4.3 Design of the Fixturing 193
10.4.4 Control of the Centering Process 194
10.4.5 Intelligent Fixturing 195
10.5 Experimental Validation 197
10.6 Conclusions 199
References 200
Summary and Conclusions 201
Author Index 203

Produkt-Details

• Erscheint lt. Verlag: 28.8.2017
• Reihe/Serie: Lecture Notes in Production Engineering
• Reihe/Serie: Lecture Notes in Production Engineering
• Zusatzinfo: XXX, 183 p. 171 illus., 166 illus. in color.
• Verlagsort: Cham
• Sprache: englisch
• Themenwelt: Technik ► Bauwesen
• Themenwelt: Technik ► Maschinenbau
• Themenwelt: Wirtschaft
• Schlagworte: Automatic machining systems • INTEFIX results • Intelligent fixture technology • Self-optimizing machining systems • Sensor and actuator integration • Simulation aided mechatronic design methods
• ISBN-10: 3-319-45291-6 / 3319452916
• ISBN-13: 978-3-319-45291-3 / 9783319452913