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Machining fixtures are used to locate the workpiece and constrain it during the machining
operation. Fixture layout is the positioning of fixturing elements such as clamps and locators. To
make sure that the workpiece is manufactured according to the specified dimensions and
tolerances, it must be appropriately located and clamped. Machining accuracy is maintained by
minimizing workpiece deformation due to cutting and clamping forces. An ideal fixture design
exhibits minimum deformation while machining. The purpose of this work is to design an
optimum fixture layout which reduces the maximum elastic deformation of the sheet metal
workpiece caused by the clamping and welding forces acting on the workpiece during welding.
This can be achieved by selecting the optimal number of fixture elements with optimum
locations. To find the optimum Fixture layout locating and clamping positions are varied with
the basic of 3-2-1 layout. In this project work, the workpiece fixture contact regions such as
clamps and locators are considered as point contact and the clamping and machining forces are
applied. Other than 3-2-1, N-2-1 locating principle is be demonstrated with sheet metal
workpiece and results are be compared. The workpiece deformation values for the various fixture
layouts are found by ANSYS. The fixture layout optimization is carried out using Response
surface methodology (RSM) to find optimum fixture layout with minimum deformation. Taguchi
method is also used to find the optimum layout using L27 orthogonal array. Then results of RSM
and Taguchi method are compared for optimum layout with minimum deformation Finally the
better locating scheme with optimum fixture layout is found for minimum deformation of the
sheet metal workpiece.
Keywords: Fixture Layout, Elastic Deformation, DOE, RSM , Sheet Metal, Taguchi
INTRODUCTION
Resistance Spot Welding (RSW) has been used for decades as a joining method for sheet
metal. Weld bonded is a combination of resistance spot welding and adhesive bonding, which
has gathered wide acceptance as an effective joining method for significant enhancement of
static, dynamic and impact resistance of the joint. It also improves the corrosion and noise
resistance as well as stiffness of the joint, compared to those observed in case of conventional
resistance spot welding. Industrial applications such as automobile and aerospace are good
examples of using weld-bonded process.
The fixture is a special tool for holding a work piece in proper position during
manufacturing operation. For supporting and clamping the work piece, device is provided.
Frequent checking, positioning, individual marking and non-uniform quality in manufacturing
process are eliminated by fixture. This increase productivity and reduce operation time. Fixture
is widely used in the industry practical production because of feature and advantages.Machining
fixture is a precision device meant for locating and constraining the workpiece during machining.
This work focuses on machining fixtures. A machining fixture is used to establish and maintain
the required position and orientation of a workpiece so that cutting operations can be performed
on the workpiece. It is a critical link in the machining system as it directly affects operational
safety and part quality. A typical machining fixture consists of a base plate and a number of
locators and clamps. Locators are passive fixture elements used to position the workpiece while
clamps are active fixture elements that can be actuated mechanically, pneumatically, or
hydraulically to apply clamping forces onto the workpiece so that it can resist external forces
generated by the machining operation. There are a variety of fixture designs. The geometry of
the contact region between a fixture element and the workpiece can be a point, line, or plane.
An important consideration in the fixture design process is to design the fixture layout.
Design of fixture layout is a procedure to establish the workpiece fixture contact through
positioning of clamps and locating elements such that the workpiece elastic deformation is
minimized. Fixture design plays an important role at the planning phase before shop floor
production. Proper fixture design is crucial to product quality in terms of precision, accuracy and
surface finish of the machined parts.
WELDING FIXTURES
Resistance spot welding represents a welding technique where the weld is made by a
combination of heat, pressure, and time. The electrical resistance of the material to be welded
causes a localized heating at the interface of the parts to be joined.
The pressure exerted by the tongs and electrode tips, through which the current flows,
holds the parts to be welded in intimate contact before, during, and after the welding current time
cycle. The actual weld nugget is formed internally with relation to the surface of the base metal.
The required amount of time current flows in the joint is determined by material thickness and
type. Figure 1 shows setup of resistance spot welding.
Fixtures are very important component in the manufacturing system. A fixture is used to
hold and locate the workpiece in the desired orientation during the manufacturing process. The
components that hold and locate the workpiece are called fixture elements. The arrangement of
these fixture elements is very important to reduce the errors in manufacturing process.
Das, Franciosa et al. (2015) proposed a new approach to improve the probability of
joining feasibility index by determining an N-2-1 fixture layout optimized for a production batch
of non-ideal sheet metal parts. The proposed methodology is based on: (i) generation of
composite parts to model shape variation within given production batch; (ii) selection of
composite assembly representing production batch; (iii) parameterization of fixture locators; and
(iv) calculation of analytical surrogate model linking composite assembly model and fixture
locators to probability of joining feasibility index. Xing, Hu et al. (2015) proposed a new
method to optimize fixture scheme by a non-domination sorting social radiation algorithm
(NSSRA). Firstly, unfeasible nodes are eliminated by four rules according to manufacturing
experiences. Afterwards, a few groups are divided based on positions of all feasible nodes. N
groups are optimized using NSSRA. Finally, the best fixture layout is generated by selecting the
feasible points among the optimal groups in last step.
Yu and Yang (2015) proposed new assembly variation modeling method of compliant
sheet metal parts combines the rigid and compliant characteristics of sheet metal parts. An
assembly variation modeling method of a rigid part under a 3-2-1 locating layout is given using
its spatial motion relationship when some fixture locating variation happens. Based on this
method, a multi-divided rigid area assembly variation modeling method can be obtained
according to part’s bending deforming principle during the locating process.
Lu and Wang (2016) proposed a positioning variation analysis approach for the sheet
metal workpiece with N-2-1 locating scheme, where the positioning process includes two stages:
deterministic positioning with 3-2-1 locating scheme and over-constraining positioning with N-
2-1 locating scheme. In positioning variation analysis, the change of the contact force between
the sheet metal workpiece and the fixture components in practical positioning process is
analyzed, the method to conclude the contact force in different positioning step is presented, and
the effect of the contact force between the sheet metal workpiece and the fixture components on
the deformation of the workpiece is considered in positioning variation analysis.
Cai (2008) developed a method for fixture optimization for sheet panel assembly considering
welding gun variations. A fixture optimization model is formulated to minimize the assembly
dimensional variations under welding gun variations. The method is verified by numerical
examples. Ma, Wang et al. (2011) presented a paper on compliant fixture layout design
using topology optimization method. This paper is mainly focused on the fixture layout design
with compliant model. A topology optimization approach is presented in order to reduce the
complexity introduced by the high computational cost of the finite element equation solving and
the exhaustive search in the point set domain. With finite element analysis, algorithms are
developed for the optimization problem of locator synthesis in the point set domain.
Cheng, Li et al. (2012) developed a fixture layout method to minimize the assembly
variation of Aeronautical Thin-Walled Structures (ATWS). This approach uses a genetic
algorithm and ant’s algorithm (GAAA) to optimize the fixture layout.Xiong, Molfino et al.
(2013) proposed a new fixture layout optimization method N-2-1-1 for flexible aerospace
workpiece. The objective function of the optimization algorithm is to minimize the maximum
elastic deformation at the machined point.Ahmad, Zoppi et al. (2013) proposed a new fixture
layout optimization method N-3-2-1 for large metal sheets that combines the genetic algorithm
and finite element analysis. The objective function is to minimize the sum of the nodal deflection
normal to the surface of the workpiece.
Roy and Liao (1999) presented a technique based on the qualitative and quantitative
reasoning to find the optimal supporting, locating, and clamping positions. Geometric reasoning
is an indispensable part of an automated fixture design system and discussed general algorithms
to verify the preliminary fixture configuration, as obtained by using 3-2-1 locating rules against
workpiece deformation and workpiece-tool interference. The paper also addresses the issues of
implementing the algorithm in a prototype, automated fixture design system.
Amaral, Rencis et al. (2005) developed a method to analyze the deformation of the
contact area between modular fixture and tool to find the optimum support locations, using finite
element analysis (FEA). ANSYS has been used for the analysis and optimization. The locators
are placed in 3-2-1 principle. The objective function of this methodology is to minimize the
maximum resultant deflection and assessing workpiece stability. Most of the above studies are
applied to the rigid bodies and use linear or nonlinear programming methods.
Li and Melkote (2001) presented an approach for fixture layout and clamping force
optimization. This approach considers the workpiece dynamics during machining. The objective
function of this approach is to minimize the maximum positional error at the machining point
during machining. An iterative fixture layout and clamping force optimization algorithm yields
the best results that are verified by simulations. Tan, Kumar et al. (2004) described an approach
for the modeling, analysis and verification of optimal fixture design. The methods of force
closure, optimization and finite element modeling (FEM) are used in this approach.
Krishnakumar and Melkote (2000) presented a fixture layout optimization technique that
uses the genetic algorithm (GA) to find the fixture layout that minimizes the deformation of the
machined surface due to clamping and machining forces over the entire tool path. Since the GA
deals with only the design variables and objective function for the particular fixture layout, no
gradient or auxiliary information is needed. The advantages of the GA-based method over
previously reported nonlinear programming methods for fixture layout optimization are
discussed. The implementation of GA is relatively straight-forward. Two GA-based fixture
layout optimization approaches are implemented and compared by applying them to several two-
dimensional example problems for entire cutting process.
Kulankara, Satyanarayana et al. (2002) has presented GA-based iterative fixture layout
and clamping force design optimization procedure for a compliant workpiece. The algorithm
minimizes the workpiece elastic deformation for the entire cutting process by alternatively
varying the fixture layout and clamping force is proposed.
Sanchez, Estrems et al. (2006) proposed two analysis methods for analyzing fixturing
systems in machining processes .This was done in order to determine the most suitable clamping
regions. The contact load at the fixture-workpiece interface is calculated first and then the valid
clamping regions are determined.
Qin, Zhang et al. (2006) presented a general analysis methodology that is able to
characterize the effects of localization source errors based on the position and orientation of the
workpiece. A comparative study was also made between the optimal solution and the empirical
one. At the end, an experiment has been made to validate the fixture locating scheme for a
cylindrical workpiece. This robust design method effectively achieves stable machining
precision in workpiece.
Kaya (2006) proposed that deformation of the workpiece may cause dimensional
problems in machining. Supports and locators are used in order to reduce the error caused by
elastic deformation of the workpiece. The optimization of support and locator locations is a
critical problem to minimize the geometric error in workpiece machining. In this paper, the
application of genetic algorithms (GAs) to the fixture layout optimization is presented to handle
fixture layout problem.
Aoyama, Kakinuma et al. (2006) the fixturing process for holding and locating workpiece
on machine tools is essential in manufacturing systems. In this study, a new fixturing support
system is proposed. The elastic deformation of the workpiece caused by the fixturing forces is
analyzed by the finite element method, and the optimum fixturing position which results in the
minimum form error of the surface to be machined is determined.
Hybrid Optimization of Pin type fixture Configuration for Free Form Workpiece was
presented by Afzeri (2008). This paper presents an automatic mechanism using pin type fixture
for holding a workpiece during machining process. The hybrid optimization algorithm is
introduced to obtain the optimum configuration of pin type fixture. Combination between
Genetic Algorithms (GAs) and Particle Swarm Optimization (PSO) algorithms is enabled to
determine optimum clamping with respect to minimum workpiece deformation. PSO rule is
further performed based on the result of GAs for obtaining global optimum of objective function.
Chen, Ni et al. (2008) presented a fixture layout design and clamping force optimization
procedure based on the GA and FEM. In which multi objective optimization procedure is used.
The objectives are minimizing the maximum deformation of the machined surfaces and
maximizing the uniformity of the deformation. The ANSYS software package has been used for
FEM calculation of fitness values.
Padmanaban, Arulshri et al. (2009) presented a Machining fixture layout design using ant
colony algorithm based continuous optimization method. In this paper, an ant colony algorithm
(ACA) based discrete and continuous optimization methods are applied for optimizing the
machining fixture layout so that the workpiece elastic deformation is minimized. The finite
element method (FEM) is used for determining the dynamic response of the workpiece caused
due to machining and clamping forces. The dynamic response of the workpiece is simulated for
all ACA runs. This paper proves that the ACA-based continuous fixture layout optimization
method exhibits the better results than that of ACA-based discrete fixture layout optimization
method.
Selvakumar, Arulshri et al. (2010), In this paper, the deformation of the workpiece can be
minimized by optimizing the parameters such as Clamping forces, Number of locators and
clamps and Positions of locators and clamps. The system gives minimum deformation when
clamping forces are minimum. The minimum clamping forces required to hold the workpiece
can be determined by using balancing force moment method and the coulomb static friction law.
Optimization of machining fixture layout for tolerance requirements under the influence of
locating errors was presented by Vishnupriyan, Majumder et al. (2010). They proposed a GA
based optimization method to arrive at a layout of error containing locators for minimum
machining error. In this work the locators are assumed to contain error in their normal direction.
This method satisfied the tolerance requirements and provided deterministic location. The fixture
layout and the corresponding machining errors were optimized.
Selvakumar, Arulshri et al. (2013) presented genetic algorithm (GA) based optimization
procedure to solve the fixture layout optimization problem is briefly explained, and then
combined GA and artificial neural network (ANN) based optimization procedure for fixture
layout design is explained. In the combined GA and ANN approach, the resulting fixture layouts
generated by GA are given as input to ANN and the maximum workpiece deformation for each
fixture layout is found out by using ANN. The optimal fixture layout is the one which shows the
minimum deformation among others. The results that are obtained by using GA and the
combination of GA and ANN are compared.
The above literature are focused on fixture layout design of fixtures using different
locating principles (3-2-1 and N-2-1). From selected locating principle suitable optimization
technique is used. Results are verified using case studies.
PROBLEM DEFINITION
To minimize the deformation of workpiece for reducing dimensional and form errors.
To find out optimum number of locators and clamps.
To select the effective locating principle.
To select the suitable optimization technique.
METHODOLOGY
Devloping a model
Optmization parameters
Optimum layout
Successful fixture designs begin with a logical and systematic plan. With a complete
analysis of the fixture's functional requirements, very few design problems occur. When they do,
chances are some design requirements were forgotten or underestimated. The workpiece,
processing, tooling and available machine tools may affect the extent of planning needed.
Preliminary analysis may take from a few hours up to several days for more complicated fixture
designs. Fixture design is a five step problem-solving process. The following is a detailed
analysis of each step. Methodology of this work is shown in figure 2.
Designing of jigs and fixtures depends upon so many factors. These factors are analyzed
to get design inputs for jigs and fixtures. The list of such factors is mentioned below:
The (3-2-1) locating principle is used to arrest the motion of workpiece. Motion is
restricted using clamps and locators. This method of locating scheme is shown in figure 3.
A three pin base can restrict five motions.
Rotation about X, Y axes (4 motions)
Translation along negative z-axis (1 motion)
Directions nine, ten and eleven are restricted by a clamping device (3 motions).
To restrict the movement of the part around the ZZ axis and in direction eight, two
more pin type locators are positioned in a vertical plane.(3 motions)
A single pin locator in vertical plane restricts motion along direction 7.
So motions in all 12 directions are restricted.
(N-2-1) method
A rigid body is fully constrained with minimum fixture elements by the 3-2-1 locating
principle. This principle is the traditional principle for locating the prismatic shaped workpieces.
According to this principle, (3, 2, 1) locators are enough to constrain the workpiece. The locating
principle 3-2-1 constrains the rigid body motion (six degree of freedom). Let us consider a sheet
metal plate. The dimensions of the sheet metal are 800mm x 600mm x 1mm are taken from
Zeshan Ahmad, Matteo Zoppi, and Rezia Molfino(2013). The finite element model of the plate
with boundary conditions is shown in Figure 5. We analyze the deformation under the self-
weight of the plate in 3-2-1 fixturing principle. The deformation results show that deformation of
the plate is very high.
N-2-1 locating principle is valid for large sheet metal parts due to their flexible nature.
According to this principle, 2-1 locators are enough to constrain the sheet metal in the secondary
and tertiary plane, but N locators are required to constrain the metal sheet in the primary plane
due to its flexible nature. The value of the N locators must be equal to or greater than 4. This
number of locators depends on the geometry and dimensional specification of the workpiece.
The boundary conditions of N-2-1 locating scheme is shown in Figure 7.
Figure 7. Boundary conditions for N-2-1 locating scheme
N-2-1 fixturing principle satisfies the two conditions required for fixturing the workpiece.
1. It constrains the workpiece fully in six degree of freedom.
The deformation of this principle is shown in Figure 8.. The arrangement of locators is very
important because the success of this principle depends on it. This arrangement can be achieved
by fixture layout optimization method.
The deformation value in this fixturing principle 1-3-2-1 is 4.5 times less than the 3-2-1
fixturing principle, which seems to be acceptable to the manufacturing process. We can reduce
this deformation more by adding more locators. It is clear that 3-2-1 locating scheme is not valid
for sheet metal due to high deformation values. Different versions of N-2-1 locating scheme can
be used for sheet metal operations.
The finite element software ANSYS 14.5 has been employed to model workpiece–fixture
system and to determine the workpiece deformation. During machining and clamp actuation, the
workpiece deformation is significantly influenced by the position of fixture elements. Hence, it is
essential to determine appropriate position for the locators and clamps to minimize the maximum
deformation of the workpiece. The flow chart for finite element analysis is shown in figure 9.
Start FEM
Workpiece modelling
Generate locator
Apply thermal force
Simulate welding
Coupled field
Deformation
The welding parameters for spot welding are given in the table 1.
The workpiece fixture system presented by Li and Tang (2006) is considered as case
study for the fixture layout optimization problem described in this work.
The geometry and features of workpiece are shown in figure 10. The material of the
workpiece is mild steel with Poisson ratio 0.3, Young’s modulus of 207 GPa and the density of
7850 kg/m³. The outline dimensions are 80×40×2 mm and 80×40×1 mm.
Parameters involved
In the fixture layout optimization problem, we need to minimize the deformation in the
sheet metal workpiece. The parameters involved which influence the deformation of the
workpiece are
Clamping forces
Welding forces
Position of locators and clamps
Material of the workpiece
Number of locators and clamps
In this work, minimum clamping forces to restrain the workpiece and the welding forces
that are required to carry out the spot welding operation is selected for analysis. The 4-2-2 fixture
layout is selected. Since this method provides maximum rigidity with the minimum number of
fixturing elements. So only by varying the positions of locators the fixture layout is optimized to
minimize the deformation of the workpiece. So the design variables are the position of the
locators and clamps.
In the fixture layout eight locators and four clamps are used to constrain the workpiece.
Each element has three coordinate values. So the number of variables will be thirty six. In all
cases, one variable in each element remain constant. Also, one more variable is assumed to be
constant. So now the design variables are reduced in to twelve.
The position of the locators and clamps and their boundary values are tabulated in table 2.
Workpiece is an elastic body whereas the fixturing elements are rigid body
The number of degree of freedom per node is three
Locators are modelled as displacement constraints that prevent workpiece translation
in the normal direction
The clamping forces are modelled as a point force acting over the workpeice-clamp
contact point
The finite-element meshes of these models are generated using eight-node-linear brick
reduced integration elements. Meshed model of the sheet metal workpiece is shown in figure 11.
A thermal analysis of heat conduction was carried out in the first step to obtain
temperature distribution histories over the structural model. Boundary conditions of transient
thermal analysis is shown in figure 5.11. The material model in which its response over the
history was determined by the temperature-dependent material properties inputted. Temperature
distribution of transient thermal analysis is shown in figure 12.
Figure 12. Boundary conditions of transient thermal analysis
In the next step, a structural analysis was carried out to obtain the mechanical response of
the structural model, where the temperature history obtained from the first step was employed as
a thermal load in the analysis. The material model in which its response over the history was
determined by the temperature-dependent material properties inputted. The boundary condition
or constraint on the structural model needs also to be assigned accordingly. Boundary conditions
for static structural analysis is shown in figure 14.
Figure 14. Boundary conditions for static structural analysis
The material model in which its response over the history was determined by the
temperature-dependent material properties inputted. The boundary condition or constraint on the
structural model needs also to be assigned accordingly. Deformation of Coupled field analysis is
shown in figure 15.
In this work, Design of Experiments (DOE) based optimization procedure is used to solve
the dimensional and form problems occur in the sheet metal spot welding assembly process.
Along with Finite element method, DOE based methodology is used to specify the optimal
locating and clamping points for minimum workpiece deformation. The preliminary experiments
are planned and conducted by systematic and random search to identify the most promising
region where the maximum workpiece deformation is minimum and is used to find the potential
range for the design parameters.
DOE is an important tool for designing processes and products. Response surface
methodology (RSM) is a collection of mathematical and statistical techniques for empirical
model building. By careful design of experiments, the objective is to optimize a response (output
variable) which is influenced by several independent variables (input variables). An experiment
is a series of tests, called runs, in which changes are made in the input variables in order to
identify the reasons for changes in the output response. The application of RSM to design
optimization is aimed at reducing the cost of expensive analysis methods and their associated
numerical noise. An advantage is the ability to handle discrete variables. The design of
experiments using RSM is shown in table 3..
The solution space for fixture layout optimization is multimodal and may contain single
or more global optima. Hence, the range for the design parameters may be as small as possible
and it has to be determined sensibly where they significantly affect the response of maximum
workpiece deformation. A main effects plot is a plot of the means of the response variable for
each level of a factor. The optimum layout suggested by RSM is shown in figure 16 and figure
17.
Design-Expert® Softw are
130.00
R1
0.0603265
R1
0.0945424
0.045649
117.75
X1 = A: A 0.0505784
X2 = B: B
Actual Factors
C: C = 28.13
B: B
105.50 0.0408304
D: D = 121.35
E: E = 31.53
F: F = 23.61
G: G = 23.38
0.0310824
Prediction 0.033194
H: H = 24.97
J: J = 5.74 93.25
K: K = 13.22
L: L = 84.38 0.0213344
M: M = 27.16
81.00
10.00 22.25 34.50 46.75 59.00
A: A
R1
0.0945424
0.045649
0.071
X1 = A: A
X2 = B: B
0.056
Actual Factors
C: C = 28.13
D: D = 121.35 0.041
R1
E: E = 31.53
F: F = 23.61
0.026
G: G = 23.38
H: H = 24.97
J: J = 5.74 0.011
K: K = 13.22
L: L = 84.38
M: M = 27.16
130.00 59.00
117.75 46.75
105.50 34.50
93.25 22.25
B: B A: A
81.00 10.00
The maximum deformation value of the optimal fixture layout was found out by using
FEA. The predicted result was verified by comparing it with the result of FEA, which shows a
reasonable agreement. Optimum position of fixturing elements suggested by RSM is shown in
table 4.
The above obtained layout is then analysed in ANSYS, deformation is taken for the
layout. The deformation of optimum fixture layout suggested by RSM is 0.035852 mm. The
deformation of analysed layout is shown in figure 18.
Figure 18 Workpiece deformation for optimum layout using RSM
The Taguchi’s method is a structural approach for determining the best combination of
inputs to produce a robust design of experiments. Taguchi's methods study the parameter space
based on the fractional factorial arrays from DoE, called orthogonal arrays. Taguchi argues that it
is not necessary to consider the interaction between two design variables explicitly, so he
developed a system of tabulated designs which reduce the number of experiments as compared to
a full factorial design. The twelve factors and three levels within the boundary values is shown in
table 6.3.
FACTORS LEVELS
1 2 3
Locator 1 (L₁) 10-26 27-43 44-59
Locator 2 (L₂) 81-97 98-113 114-130
Locator 3 (L₃) 10-26 27-43 44-59
Locator 4 (L₄) 81-97 98-113 114-130
Locator 5 (L₅) 81-97 98-113 114-130
Locator 6 (L₆) 5-15 16-25 26-35
Locator 7 (L₇) 5-15 16-25 26-35
Locator 8 (L₈) 5-15 16-25 26-35
Clamp 1 (C₁) 5-15 16-25 26-35
Clamp 2 (C₂) 10-26 27-43 44-59
Clamp 3 (C₃) 81-97 98-113 114-130
Clamp 4 (C₄) 5-15 16-25 26-35
Software used: MINITAB
Method used: L27 Orthogonal array
Factors – 12
Levels – 3
No of runs – 27
Table 6. Taguchi L27 Orthogonal array
A B C D E F G H J K L M (mm)
1 1 1 1 1 1 1 1 1 1 1 1 1 0.056231597
2 1 1 1 1 2 2 2 2 2 2 2 2 0.062051599
3 1 1 1 1 3 3 3 3 3 3 3 3 0.067509823
4 1 2 2 2 1 1 1 2 2 2 3 3 0.079789374
5 1 2 2 2 2 2 2 3 3 3 1 1 0.063177853
6 1 2 2 2 3 3 3 1 1 1 2 2 0.069841153
7 1 3 3 3 1 1 1 3 3 3 2 2 0.079244183
8 1 3 3 3 2 2 2 1 1 1 3 3 0.075329477
9 1 3 3 3 3 3 3 2 2 2 1 1 0.082463173
10 2 1 2 3 1 2 3 1 2 3 1 2 0.057517396
11 2 1 2 3 2 3 1 2 3 1 2 3 0.067550254
12 2 1 2 3 3 1 2 3 1 2 3 1 0.083025514
13 2 2 3 1 1 2 3 2 3 1 3 1 0.077137286
14 2 2 3 1 2 3 1 3 1 2 1 2 0.067318978
15 2 2 3 1 2 3 1 3 1 2 1 2 0.07894879
16 2 2 3 1 3 1 2 1 2 3 2 3 0.078153523
17 2 3 1 2 1 2 3 3 1 2 2 3 0.06846326
18 2 3 1 2 2 3 1 1 2 3 3 1 0.081220156
19 2 3 1 2 3 1 2 2 3 1 1 2 0.074631233
20 3 1 3 2 1 3 2 1 3 2 1 3 0.065215118
21 3 1 3 2 2 1 3 2 1 3 2 1 0.076454197
22 3 1 3 2 3 2 1 3 2 1 3 2 0.073673351
23 3 2 1 3 1 3 2 2 1 3 3 2 0.072766362
24 3 2 1 3 2 1 3 3 2 1 1 3 0.068651562
25 3 2 1 3 3 2 1 1 3 2 2 1 0.070124427
26 3 3 2 1 1 3 2 3 2 1 2 1 0.066828504
27 3 3 2 1 2 1 3 1 3 2 3 2 0.057246172
To select an appropriate orthogonal array for conducting the experiments, the degrees of
freedom are to be computed. The experimental design proposed by Taguchi involves using
orthogonal arrays to organize the parameters affecting the process and the levels at which they
should be varied. Instead of having to test all possible combinations like the factorial design, the
Taguchi method tests pairs of combinations. L27 Orthogonal array is selected and is shown in
table 6.4.
The Full Factorial Design requires a large number of experiments to be carried out as
stated above. It becomes laborious and complex, if the number of factors increase. To overcome
this problem Taguchi suggested a specially designed method called the use of orthogonal
array to study the entire parameter space with lesser number of experiments to be
conducted. Taguchi thus, recommends the use of the loss function to measure the performance
characteristics that are deviating from the desired target value. The value of this loss function
is further transformed into signal-to-noise (S/N) ratio. Usually, there are three categories of
the performance characteristics to analyze the S/N ratio. They are: nominal-the-best, larger-the-
better, and smaller-the-better. Optimum parameter values are obtained using S/N ratio graphs
shown in figure 6.4.
From the selected level of factors, it is again divided into three level parameter
optimization is carried. The design variable range for second iteration is shown in table 8.
FACTORS LEVELS
1 2 3
Locator 1 (L₁) 44-49 50-54 55-59
Locator 2 (L₂) 81-86 87-92 93-97
Locator 3 (L₃) 27-32 33-38 39-43
Locator 4 (L₄) 81-86 87-92 93-97
Locator 5 (L₅) 16-19 20-22 23-25
Locator 6 (L₆) 16-19 20-22 23-25
Locator 7 (L₇) 5-8 9-12 13-15
Locator 8 (L₈) 5-8 9-12 13-15
Clamp 1 (C₁) 5-8 9-12 13-15
Clamp 2 (C₂) 44-49 50-54 55-59
Clamp 3 (C₃) 81-86 87-92 93-97
Clamp 4 (C₄) 5-8 9-12 13-15
A B C D E F G H J K L M (mm)
1 1 1 1 1 1 1 1 1 1 1 1 1 0.038901369
2 1 1 1 1 2 2 2 2 2 2 2 2 0.049697361
3 1 1 1 1 3 3 3 3 3 3 3 3 0.05611115
4 1 2 2 2 1 1 1 2 2 2 3 3 0.069694638
5 1 2 2 2 2 2 2 3 3 3 1 1 0.07200314
6 1 2 2 2 3 3 3 1 1 1 2 2 0.067393299
7 1 3 3 3 1 1 1 3 3 3 2 2 0.083381331
8 1 3 3 3 2 2 2 1 1 1 3 3 0.073902635
9 1 3 3 3 3 3 3 2 2 2 1 1 0.066133136
10 2 1 2 3 1 2 3 1 2 3 1 2 0.063673053
11 2 1 2 3 2 3 1 2 3 1 2 3 0.053350395
12 2 1 2 3 3 1 2 3 1 2 3 1 0.050657117
13 2 2 3 1 1 2 3 2 3 1 3 1 0.063086202
14 2 2 3 1 2 3 1 3 1 2 1 2 0.056810424
15 2 2 3 1 2 3 1 3 1 2 1 2 0.062805153
16 2 2 3 1 3 1 2 1 2 3 2 3 0.065256123
17 2 3 1 2 1 2 3 3 1 2 2 3 0.071654007
18 2 3 1 2 2 3 1 1 2 3 3 1 0.067684808
19 2 3 1 2 3 1 2 2 3 1 1 2 0.056453553
20 3 1 3 2 1 3 2 1 3 2 1 3 0.054864226
21 3 1 3 2 2 1 3 2 1 3 2 1 0.058512746
22 3 1 3 2 3 2 1 3 2 1 3 2 0.05230659
23 3 2 1 3 1 3 2 2 1 3 3 2 0.048075713
24 3 2 1 3 2 1 3 3 2 1 1 3 0.057857846
25 3 2 1 3 3 2 1 1 3 2 2 1 0.06875697
26 3 3 2 1 1 3 2 3 2 1 2 1 0.05239189
27 3 3 2 1 2 1 3 1 3 2 3 2 0.055703324
Figure 20. Optimum value of parameters (Iteration 2)
Optimum parameter values are obtained using S/N ratio graphs shown in figure 6.4.
Optimum parameter levels for L27 array (Iteration2) =A3B1C1D1E2F1G3H2J1K2L1M1 is
selected on first iteration. The selected level of first iteration in shown in table 10.
FACTORS LEVELS
1 2 3
Locator 1 (L₁) 55-56 57-58 59
Locator 2 (L₂) 81-82 83-84 85-86
Locator 3 (L₃) 27-28 29-30 31-32
Locator 4 (L₄) 81-82 83-84 85-86
Locator 5 (L₅) 20 21 22
Locator 6 (L₆) 16-17 18 19
Locator 7 (L₇) 13 14 15
Locator 8 (L₈) 9-10 11 12
Clamp 1 (C₁) 5-6 7 8
Clamp 2 (C₂) 50-51 52-53 54
Clamp 3 (C₃) 81-82 83-84 85-86
Clamp 4 (C₄) 5-6 7 8
A B C D E F G H J K L M (mm)
1 1 1 1 1 1 1 1 1 1 1 1 1 0.064857
2 1 1 1 1 2 2 2 2 2 2 2 2 0.043736
3 1 1 1 1 3 3 3 3 3 3 3 3 0.036813
4 1 2 2 2 1 1 1 2 2 2 3 3 0.045631
5 1 2 2 2 2 2 2 3 3 3 1 1 0.049123
6 1 2 2 2 3 3 3 1 1 1 2 2 0.04553
7 1 3 3 3 1 1 1 3 3 3 2 2 0.063457
8 1 3 3 3 2 2 2 1 1 1 3 3 0.058413
9 1 3 3 3 3 3 3 2 2 2 1 1 0.053643
10 2 1 2 3 1 2 3 1 2 3 1 2 0.038756
11 2 1 2 3 2 3 1 2 3 1 2 3 0.051163
12 2 1 2 3 3 1 2 3 1 2 3 1 0.040348
13 2 2 3 1 1 2 3 2 3 1 3 1 0.05459
14 2 2 3 1 2 3 1 3 1 2 1 2 0.05184
15 2 2 3 1 2 3 1 3 1 2 1 2 0.053827
16 2 2 3 1 3 1 2 1 2 3 2 3 0.034853
17 2 3 1 2 1 2 3 3 1 2 2 3 0.049813
18 2 3 1 2 2 3 1 1 2 3 3 1 0.044615
19 2 3 1 2 3 1 2 2 3 1 1 2 0.044745
20 3 1 3 2 1 3 2 1 3 2 1 3 0.034567
21 3 1 3 2 2 1 3 2 1 3 2 1 0.04348
22 3 1 3 2 3 2 1 3 2 1 3 2 0.04737
23 3 2 1 3 1 3 2 2 1 3 3 2 0.049732
24 3 2 1 3 2 1 3 3 2 1 1 3 0.047039
25 3 2 1 3 3 2 1 1 3 2 2 1 0.052926
26 3 3 2 1 1 3 2 3 2 1 2 1 0.054167
27 3 3 2 1 2 1 3 1 3 2 3 2 0.062311
Optimum parameter values are obtained using S/N ratio graphs shown in figure 21.
Optimum parameter levels for L27 array (Iteration3) = A2B1C1D2E3F2G3H3J1K2L2M2 is
selected on first iteration. The selected level of first iteration in shown in table 13
Table 13. Optimum parameter level from iteration 3
From the selected level of factors, it is again divided into three level parameter
optimization is carried. The design variable range for fourth iteration is shown in table 6.14
FACTORS LEVELS
1 2 3
Locator 1 (L₁) 57 57.5 58
Locator 2 (L₂) 81 81.5 82
Locator 3 (L₃) 27 27.5 28
Locator 4 (L₄) 83 83.5 84
Locator 5 (L₅) 22 22 22
Locator 6 (L₆) 18 18 18
Locator 7 (L₇) 15 15 15
Locator 8 (L₈) 12 12 12
Clamp 1 (C₁) 5 5.5 6
Clamp 2 (C₂) 52 52.5 53
Clamp 3 (C₃) 83 83.5 84
Clamp 4 (C₄) 7 7 7
A B C D E F G H J K L M (mm)
1 1 1 1 1 1 1 1 1 1 1 1 1 0.037803
2 1 1 1 1 2 2 2 2 2 2 2 2 0.039526
3 1 1 1 1 3 3 3 3 3 3 3 3 0.037799
4 1 2 2 2 1 1 1 2 2 2 3 3 0.045186
5 1 2 2 2 2 2 2 3 3 3 1 1 0.036385
6 1 2 2 2 3 3 3 1 1 1 2 2 0.036769
7 1 3 3 3 1 1 1 3 3 3 2 2 0.041584
8 1 3 3 3 2 2 2 1 1 1 3 3 0.044141
9 1 3 3 3 3 3 3 2 2 2 1 1 0.037311
10 2 1 2 3 1 2 3 1 2 3 1 2 0.038337
11 2 1 2 3 2 3 1 2 3 1 2 3 0.038472
12 2 1 2 3 3 1 2 3 1 2 3 1 0.042895
13 2 2 3 1 1 2 3 2 3 1 3 1 0.036207
14 2 2 3 1 2 3 1 3 1 2 1 2 0.036612
15 2 2 3 1 2 3 1 3 1 2 1 2 0.038924
16 2 2 3 1 3 1 2 1 2 3 2 3 0.039831
17 2 3 1 2 1 2 3 3 1 2 2 3 0.042489
18 2 3 1 2 2 3 1 1 2 3 3 1 0.039646
19 2 3 1 2 3 1 2 2 3 1 1 2 0.036969
20 3 1 3 2 1 3 2 1 3 2 1 3 0.037504
21 3 1 3 2 2 1 3 2 1 3 2 1 0.040276
22 3 1 3 2 3 2 1 3 2 1 3 2 0.04565
23 3 2 1 3 1 3 2 2 1 3 3 2 0.035852
24 3 2 1 3 2 1 3 3 2 1 1 3 0.038505
25 3 2 1 3 3 2 1 1 3 2 2 1 0.037148
26 3 3 2 1 1 3 2 3 2 1 2 1 0.039592
27 3 3 2 1 2 1 3 1 3 2 3 2 0.037286
Figure 22. Optimum value of parameters (Iteration 4)
Optimum parameter values are obtained using S/N ratio graphs shown in figure 22.
Optimum parameter levels for L27 array (Iteration4) = A3B2C3D1E3F3G3H3J3K1L1M1 is
selected on first iteration. The selected level of first iteration in shown in table 6.14.
The maximum deformation value of the optimal fixture layout was found out by using
FEA. The predicted result was verified by comparing it with the result of FEA, which shows a
reasonable agreement. The optimum layout for minimum deformation is given in the table 17.
Locator 1 (L₁) 58
Locator 3 (L₃) 28
Locator 4 (L₄) 83
Locator 5 (L₅) 22
Locator 6 (L₆) 18
Locator 7 (L₇) 15
Locator 8 (L₈) 12
Clamp 1 (C₁) 6
Clamp 2 (C₂) 52
Clamp 3 (C₃) 83
Clamp 4 (C₄) 7
The above obtained layout is then analysed in ANSYS, deformation is taken for the
layout. The deformation of optimum fixture layout suggested by Taguchi is 0.03708 mm. The
deformation of analysed layout is shown in figure 23.
Figure 23. Workpiece deformation for optimum layout using Taguchi method
The optimum fixture layout of RSM and Taguchi method are compared in table 6.16. The
minimum deformation of optimum fixture layout obtained from RSM and Taguchi indicating
RSM having minimum deformation of optimum fixture layout.
From the above obtained deformation values of optimum layouts using RSM and
Taguchi’s method. Percentage reduction in deformation is calculated and shown below, the
percentage reduction is about 3.45%.
= 3.45%
CONCLUSION
In this work, an effective attempt is made to model the workpiece-fixture interaction and
to optimize fixture layout using RSM and Taguchi methods. The purpose of this work is to
design an optimum fixture in order to reduce the maximum elastic deformation of the workpiece
caused by the clamping and welding forces acting on the workpiece while welding. In this
project work the optimization procedure to solve the fixture design problem is briefly explained.
The number of fixture elements and layouts are to be changed and the procedure is repeated until
minimum deformation is reached.
While comparing 3-2-1 and N-2-1 locating schemes, N-2-1 locating scheme provides
better rigidity for sheet metal. It is clearly indicating N-2-1 locating scheme gives 4.5
times less deformation for sheet metal workpiece.
In design of experiments, optimization is carried out using RSM and Taguchi method.
From the obtained optimum fixture layout, minimum deformation values are taken from
ANSYS results. It shows RSM provides lesser deformation 3.45% than Taguchi method
for selected fixture layout.
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