MACHINING FEATURE BASED CLAMPING FORCE OPTIMIZATION

摘要

In order to improve machining accuracy, appropriate magnitudes of clamping forces and methods of application are studied in this research. The objective of this study is to find a minimum clamping load that must be applied to keep a workpiece in static equilibrium and to assure that the total workpiece deformation is minimized in a machining process. In particular, a machining feature-based clamping force optimization model is presented for this purpose. Through cutting experiments, the maximum cutting forces occurred in different directions for each machining feature. These maximum cutting forces are measured and integrated into a machining feature-based cutting force database. The deformation of a workpiece is then estimated using finite element analysis, when clamping force and cutting force along tool path are loaded. Finally, by combining the results of the above two steps, a mathematical optimization model is formulated. This model not only makes it possible to minimize the workpiece's deformation under several cutting operations of machining features in one machining process, but it also finds optimum clamping forces exerted at the contact regions.