Collision-free machining fixture space design based on parametric tool space for five-axis grinding

As one of the most important criteria of fixture performance, there should be no collision between fixtures, tool, component and machine. Conventionally, fixture space design is treated as an isolated process from the design of tooling strategy, and the iteration of fixture re-design and re-manufacturing until a satisfactory fixture is achieved is very time-consuming and error-prone. In this paper, a novel method of fixture space design is proposed. Starting from the minimal number of set-ups, the tool spaces for all the machining features are generated parametrically by sweeping the wheel profile along the wheel trajectory. The fixture space is the remaining space after the tool space is deduced from the total working space. Therefore, the fixture space is, by nature, collision-free from the tool movement. The fixture space and the tool space can be designed interactively until the number of set-ups is minimal and an optimal system of fixture-tool-component is obtained in terms of the overall system performance. The fixture development for aerofoil blades is used as case study.