Presented by:

Yuezhuang Kang
December 7, 2001
Worcester Polytechnic Institute
Computer-Aided Fixture Design Verification
(CAFDV)
Introduction Fixture and CAFDV
Fixture the device that locates and holds the workpiece
during its machining process.
Computer-Aided Fixture
Design (CAFD) uses
computer to reduce lead time
and ensure fixture design
quality.
Fixture design has large impact on product quality,
manufacturing lead time and cost.
Introduction 4 Stages of CAFD
Setup Planning
determines number of setups
determines machining features of each setup
Fixturing Planning
finds fixturing surfaces and positions
Configuration Design
constructs detailed fixture geometries
Verification (CAFDV)
verifies (and improves) fixture designs
CAFDV Overview
Introduction Modeling Applications Implementations
CAFDV is studied systematically for the first time.
This presentation is organized by levels above.
Geometric Model
(Jacobian Matrix)
Kinetic Model
(Fixture Stiffness Matrix)
Locating
Performance
Tolerance
Verification
Stability
Verification
Major
Applications
Models
Other
Applications
Locator Layout
Optimization
Locator Tolerance
Assignment
Clamping Force
Optimization
Literatures Geometric Model
The Jacobian Matrix (Asada and By, 1985)
Workpiece DOFs constrained by fixture
Locating completeness
The Grasp Matrix (Xiong 1998, 1999)
Locating Performance Index (Stability Index)
Locator Layout Optimization
In this study:
The Jacobian Matrix is extended for tolerance analysis
An algorithm of finding the Jacobian Matrix is implemented
Introduction Modeling Applications Implementations
Literatures
Introduction Modeling Applications Implementations
Literatures
Studies Relate to
Fixturing Stability
F
r
i
c
t
i
o
n

f
o
r
c
e

W
o
r
k
p
i
e
c
e

d
e
f
o
r
m
a
t
i
o
n

F
i
x
t
u
r
e

d
e
f
o
r
m
a
t
i
o
n

C
l
a
m
p
i
n
g

s
e
q
u
e
n
c
e

Lee and Cutkosky, 1991 X - - -
Cogun, 1992 - - - X
Trappey and Liu, 1992 X - - -
Rong et al, 1994 X - - -
Chen, 1995 - - - X
Wu et al, 1995 X - - -
DeMeter, 1998 - X - -
Kashyap and DeVries, 1999 - X - -
CAFDV X - X X

Literatures Kinetic Model
All previous stability related studies consider no deformation or
only workpiece deformation. This study fills the blank with
consideration on fixture deformation.
Workpiece
deformation has
been and can only
be solved with FEA.
Introduction Modeling Applications Implementations
Literatures
Datum Establish Error (Choudhuri and DeMeter 1999)
Used planar bounding surfaces for simple and fast estimation
For planar datum and machining surfaces only
Reference Planes three orthogonal planes (Rong et al, 1996)
Works with any type of datum surface
Includes only predefined locating modes
This work uses the Jacobian Matrix and contact points:
Works with any type of surface and locating mode
Defines surface tolerance by surface sample points
Calculates sensitivity for tolerance assignment
Literatures Tolerance Analysis
Literatures Locator Types
Locator Locating Points
Geometry Constrains
Tolerance
Stiffness
Most earlier studies all locators are assumed to be points.
Wu et al (1995) used lines and surfaces to represent
locators, however, non-geometry information are lost.
This study allows any type of locator, which is converted
into equivalent locating points with all necessary information.
Introduction Modeling Applications Implementations
Literatures
Literatures Summary
Introduction Modeling Applications Implementations
Literatures
The Geometric Model (the Jacobian Matrix):
The Jacobian Matrix is extended for tolerance analysis
An algorithm of finding the Jacobian Matrix is implemented
The Kinetic Model:
Fixture deformation is considered for the first time
The Fixture Stiff Matrix is created to link external forces with
fixture deformation (and workpiece displacement)
Tolerance Analysis:
Uses the Jacobian Matrix
Locator tolerances are assigned based on sensitivity analysis
Locator Types:
All types of locators are allowed, and they are converted into
locating points with all necessary information
Modeling for CAFDV
Introduction Modeling Applications Implementations
Geometric Fixture Model
Describes the relationship between workpiece
displacement and locator displacements.
Kinetic Fixture Model
Describes the relationship between external forces and
workpiece displacement.
Geometric Fixture Model
Introduction Modeling Applications Implementations
Geometric Fixture Model

L
2
L
1
L
3
WCS

GCS

WCS workpiece coordinate system
GCS global coordinate system
{d} = [J] {q}
[J] the Jacobian Matrix
{q} = [J]
-1
{d}
Locating Point
Displacements
Workpiece
Displacements
{ } { }
T
z y x q = { } { }
n 2 1
d d d d =

The Jacobian Matrix

Introduction Modeling Applications Implementations
Geometric Fixture Model
{d} = [J] {q}

d
x
d

d
x
d

d
z
d
y
d
x
d
J
n m
2 2
1 1 1 1 1 1

Kinetic Fixture Model Overview
Introduction Modeling Applications Implementations
Kinetic Fixture Model
| | { } { }
e
W q K =
{ } { }
T
ez ey ex ez ey ex e
M , M , M , F , F , F W = extern wrench (gravity, clamping and cutting forces)
{ } { }
T
, , z, y, x, q =
workpiece displacement
| | K the Fixture Stiffness Matrix
Locator Clamp
External
Forces
Workpiece
Displacements
Three Types of Coordinate Systems
Introduction Modeling Applications Implementations
Kinetic Fixture Model

u
v
w
x
y
z
GCS
x
y
z
LCS
WCS
Global coordinate system (GCS) the fixed CS in 3D space.
Workpiece coordinate system (WCS) the CS attached to each workpiece.
Local coordinate system (LCS) the CS attached to each contact point.
Finding Fixture Stiffness Matrix
Step 1. Find Contact Point Displacement in GCS
Introduction Modeling Applications Implementations
Kinetic Fixture Model

u
v
w
x
y
z
GCS
x
y
z
LCS
WCS
{ } | | { } q J
p
p
p
p
G
z
G
y
G
x
G
i
=

=
| | { } { } { } { } { } { }

=
W
w
W
w
W
w
W
w
W
w
W
w
p

T
p

T
p

T
p
z
T
p
y
T
p
x
T
J
Finding Fixture Stiffness Matrix
Step 2. Transform Point Displacement into LCS
Introduction Modeling Applications Implementations
Kinetic Fixture Model

u
v
w
x
y
z
GCS
x
y
z
LCS
WCS
{ } | | { }
G
1
L
G
L
p T p =

Finding Fixture Stiffness Matrix
Step 3. Find Contact Forces in LCS
Introduction Modeling Applications Implementations
Kinetic Fixture Model
{ } | | { }
L
i
i
L
iz
L
iy
L
ix
iz
iy
ix
L
iz
L
iy
L
ix
L
i
p k
p
p
p
k 0 0
0 k 0
0 0 k
f
f
f
f =

z
y
x
z
y
x
z
y
x
d
d
d
k 0 0
0 k 0
0 0 k
f
f
f
Finding Fixture Stiffness Matrix
Step 4. Transform Contact Forces into GCS
Introduction Modeling Applications Implementations
Kinetic Fixture Model

u
v
w
x
y
z
GCS
x
y
z
LCS
WCS
{ } | | } {f T f
L
i
L
Gi i
=
Finding Fixture Stiffness Matrix
Step 5. Combine Contact Forces into Internal Wrench
Introduction Modeling Applications Implementations
Kinetic Fixture Model

u
v
w
x
y
z
GCS
x
y
z
LCS
WCS
{ } | | { }
i i
iz
iy
ix
i i
i i
i i
iz
iy
ix
iz
iy
ix
i
f
f
f
f
0 x y -
x - 0 z
y z - 0
1 0 0
0 1 0
0 0 1
M
M
M
F
F
F
W =

=
Finding Fixture Stiffness Matrix Result
Introduction Modeling Applications Implementations
Kinetic Fixture Model
{ }
| | { }
| | | | { }
| | | | | | { }
| | | | | | | | { }
| | | | | | | | | | { }
w
1
L
G
L L
G
G
1
L
G
L L
G
L L L
G
L L
G
G
in
q J R k R
p R k R
p k R
f R
f
W
=
=
=
=
=

{ } { } | | { } q K W W
e in
= =
| | | | | | | | | | J R k R [K]
1
L
G
L L
G
=

Contact Forces
Introduction Modeling Applications Implementations
Kinetic Fixture Model
{ } | | | | | | { } q J T k f
1
L
G
L
=

Contact Force in LCS (essential in stability verification):
{d} = [J]
{q}
{q} = [J]
-1
{d}
| | | | | | | | | | J R k R [K]
1
L
G
L L
G
=

| | { } { }
e
W q K =
Fixture Modeling Summary
Geometric Model:
Kinetic Model:
Introduction Modeling Applications Implementations
Locating Point
Displacements
Workpiece
Displacements
External
Forces
Workpiece
Displacements
CAFDV Applications
Introduction Modeling Applications Implementations
Locating
Performance
Tolerance
Verification
Stability
Verification
Major
Applications
Other
Applications
Locator Layout
Optimization
Locator Tolerance
Assignment
Clamping Force
Optimization
Locator Tolerance Verification
Introduction Modeling Applications Implementations

T
L
2
L
1
L
3
P
1
P
2
WCS

GCS

Verifies if the locator tolerances can ensure machining surface
accuracy.
Surface Deviation
Introduction Modeling Applications Implementations
Tolerance Verification
{ } | | { } d J q
1
=

( ) | | ( ) | |
( ) ( ) | |
| | { } ( ) ( ) | |
W
i 0
W
G
1
0
W
G
G
i
W
i 0
W
G 0
W
G
G
i
W
i 0
W
G
W
i 0
W
G
G
i1
G
i2
G
i
P q T d J q T P
P q T q q T P
P q T P q q T P P P
+ =
+ =
+ = =

Find machining surface
sample points
Step 1.
Step 2.
Step 3.
i i
n
i
n p p =
Step 4.
Find workpiece
displacement
Find sample point
displacements
Find point displacements
along surface normal
Surface Deviation and Accuracy
Introduction Modeling Applications Implementations
Tolerance Verification

p
i

axis
p
i

d
i

axis deviated
Surface and Line Profile
Parallelism, Perpendicularity and Angularity
True Positioning Deviation
Definitions follow ANSI Y-14.5 standards.
{ }
n
n
n
2
n
1
p p p max 2 dev =
{ }
n
n
n
2
n
1
d d d max 2 dev =

{ } { }
n
n
n
2
n
1
n
n
n
2
n
1
p p p min p p p max dev =
{ }
m 2 1
dev dev dev max acc =

Machining Surface Accuracy

Tolerance Verification Summary
Introduction Modeling Applications Implementations

T
L
2
L
1
L
3
P
1
P
2
WCS

GCS

Locator Error
Locating Point Displacements
Workpiece Displacement
Sample Point Displacements
Machining Surface Deviations
Machining Surface Accuracy
Stability Verification
Introduction Modeling Applications Implementations
To verify if the workpiece remains stable under external
forces (gravity, clamping and cutting forces).
Stability Criteria
Introduction Modeling Applications Implementations
Machining Stability
Friction Cone
Workpiece Stability Criteria No slippery at any
contact point, i.e., the reaction force at each contact
point should fall within its friction cone.
{ } | | | | | | { } q J T k f
1
L
G
L
=

Contact Force in LCS:
Contact Stability Index (CSI)
Introduction Modeling Applications Implementations
Machining Stability
CSI is a normalized measurement of a contact point stability.

>

=
0 F
0
0 F
0 F
0
F

1.0
CSI
-1 CSI < 0 outside the friction cone, unstable
CSI = 0 on the friction cone, marginally stable
0 < CSI 1 inside the friction cone, stable
Stability Verification Summary
Introduction Modeling Applications Implementations
Stability Criteria
All contact forces should fall within its friction cone,
i.e., CSI > 0.
Locating Performance
Introduction Modeling Applications Implementations
Locating Performance
How to measure this intuitive stability?
Locating Performance Index (LPI)
Introduction Modeling Applications Implementations
Locating Performance
| | ( ) | | | |) J J det( J gram LPI
T
= =
[J] is the Jacobian Matrix
det is the determinant of a matrix
gram is the grammian of a matrix
{ } | | { } q J d =
{ } | | { } | | ( ) { } | | ( ) { } q J gram q J gram q J d
2 2
= = =
{ } { } q LPI d =
CAFDV Applications Summary
Introduction Modeling Applications Implementations
Tolerance
Verification
Locator Error Machining Surface Accuracy
Stability
Verification
At all contact points, CSI > 0
Locating
Performance
| | ( ) | | | |) J J det( J gram LPI
T
= =
To maximize
CAFDV Implementation Issues
Introduction Modeling Applications Implementations
Conversion between locator and locating points
Software Design
Software User Interface
Locator and Locating Points
Introduction Modeling Applications Implementations
Locator Conversion
Seven types of locators are implemented.
Locators are converted into points for fixture models.
Conversions between locator and its equivalent locating points:
geometry conversion
tolerance conversion
stiffness conversion
Geometric Conversion
A locator and its equivalent locating points constrain the same
number of DOFs of the workpiece.
Introduction Modeling Applications Implementations
Locator Conversion
Tolerance Conversion V-Block Type

DD

P
1
d
1(3)

P
2
d
2(4)

HH
WW
( )
( ) ( )
( ) | |
( )

=


+

+ =
W d
2 cos 1 4
2 cos D
2
2 sin D
H d
4 2
2
3 1
( )
( )
{ }

=
=
=
=
3 d d min t where,
D t
2 cos t W
2 sin t H
2 1
Introduction Modeling Applications Implementations
Locator Conversion
A locator and its equivalent locating points provide the same level
of locating accuracy.
Stiffness Conversion V-Pad Type

W
H
L
D
T
x
y
z
D/5 3 T
D H
2D/5 W/5 L
2D W
=
=
= =
=

+ =
+ =
+ =
W 05 6.54E Sy
W 06 1.48E Sx
W 06 4.83E Sz
Introduction Modeling Applications Implementations
Locator Conversion
Note: The results are based on ANSYS FEA results, with material as steel.
A locator and its equivalent locating points provide the same level
of stiffness.
Software Design System Architecture

UI
FLTK
CAD
OPEN I-DEAS
GU
FIXTURE
Operating System
Modularized Design to maximize the portability and
reusability
Introduction Modeling Applications Implementations
Software Design
User Interface Integration with CAD
Introduction Modeling Applications Implementations
User Interface Design
CAFDV Task Menu
Introduction Modeling Applications Implementations
User Interface Design
This implementation
contains five modules.
Accessibility
Panel and
Locator
Selection
Introduction Modeling Applications Implementations
User Interface Design
Seven types of locators
and equivalent locating
points
Locator
Selection
Introduction Modeling Applications Implementations
User Interface Design
CAD
interaction
Locator Details
Introduction Modeling Applications Implementations
User Interface Design
Each locator has its own
tolerance specification
Tolerance
Analysis and
Tolerance
Types
Introduction Modeling Applications Implementations
User Interface Design
Tolerance
Assignment
and Locator
Tolerance
Introduction Modeling Applications Implementations
User Interface Design
Locator with
assigned tolerances
Stability Analysis
Introduction Modeling Applications Implementations
User Interface Design
Summary
The first systematic study of CAFDV
Reformulation of fixturing problems with two models
Establishment of the Jacobian Matrix and the Fixture Stiffness Matrix
CAD Integration successfully integrated with CAD package
Tolerance analysis
Tolerance analysis with the Jacobian Matrix
Tolerance assignment with sensitivity analysis
Stability analysis
Handling of 3-D, frictional, and over-constraint problems
Consideration of clamping sequence
Optimization for minimal clamping forces
Loading/Unloading accessibility
Stability dynamics and workpiece deformation
Tolerance consideration of fixture deformation
Future Work
Questions?