Design and optimization of machining fixture layout for end-milling operation

High product quality and productivity are the important objectives of manufacturing industries. They are greatly affected by the fixture layout design, and it requires modeling and analysis of fixture-workpiece interactions. In particular, the position of fixture elements has explicit influence on the deformation of the workpiece which needs to be minimized during machining. In order to ensure effective fixture layout design, the relationship between the position of fixture elements and workpiece deformation has to be modeled and optimized. In this research paper, workpiece deformation is modeled using response surface methodology. The developed model is tested for model adequacy, and the results obtained are matched with the simulated data. Then, it is used to minimize the workpiece deformation by determining the appropriate positions of locators and clamps using sequential approximation optimization and LINGO solver. It is found that integration of response surface methodology, with sequential approximation optimization, produces better results than LINGO solver.