Intelligent Fixtures for High Performance Machining

Abstract

Fixtures are an essential element of the machining system, being part of the precision path and force flux between process and machine tool. Intelligent fixtures enable the identification of critical process conditions, a compensation of error influences and the minimization of defective parts. At first, this contribution presents a study in which the influence of the clamping setup and of the workpiece characteristics at various steps of the machining process is analyzed. Experimental and theoretical results regarding the dynamic process behavior reveal the relevance of these influences with respect to machining performance and workpiece quality. Secondly, the European research project INTEFIX is introduced. Representative approaches of intelligent fixtures, reducing workpiece vibrations and distortions, and improving workpiece alignment, are described and prototypes are shown. In a third part, two examples of intelligent fixtures are presented and discussed more in detail. The first example concerns a fixture for the identification and active mitigation of chatter in milling of thin walled workpieces. The second example is related to the compensation of workpiece distortions which occur in machining of large thin walled structural parts.