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Frontiers of Mechanical Engineering

ISSN 2095-0233

ISSN 2095-0241(Online)

CN 11-5984/TH

Postal Subscription Code 80-975

2018 Impact Factor: 0.989

Front. Mech. Eng.    2022, Vol. 17 Issue (4) : 55    https://doi.org/10.1007/s11465-022-0711-5
REVIEW ARTICLE
Fixturing technology and system for thin-walled parts machining: a review
Haibo LIU, Chengxin WANG, Te LI, Qile BO, Kuo LIU, Yongqing WANG()
Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024, China
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Abstract

During the overall processing of thin-walled parts (TWPs), the guaranteed capability of the machining process and quality is determined by fixtures. Therefore, reliable fixtures suitable for the structure and machining process of TWP are essential. In this review, the key role of fixtures in the manufacturing system is initially discussed. The main problems in machining and workholding due to the characteristics of TWP are then analyzed in detail. Afterward, the definition of TWP fixtures is reinterpreted from narrow and broad perspectives. Fixture functions corresponding to the issues of machining and workholding are then clearly stated. Fixture categories are classified systematically according to previous research achievements, and the operation mode, functional characteristics, and structure of each fixture are comprehensively described. The function and execution mode of TWP fixtures are then systematically summarized and analyzed, and the functions of various TWP fixtures are evaluated. Some directions for future research on TWP fixtures technology are also proposed. The main purpose of this review is to provide some reference and guidance for scholars to examine TWP fixtures.

Keywords thin-walled part (TWP)      fixture      machining      fixture categories      fixture function     
Corresponding Author(s): Yongqing WANG   
Just Accepted Date: 12 July 2022   Issue Date: 06 January 2023
 Cite this article:   
Haibo LIU,Chengxin WANG,Te LI, et al. Fixturing technology and system for thin-walled parts machining: a review[J]. Front. Mech. Eng., 2022, 17(4): 55.
 URL:  
https://academic.hep.com.cn/fme/EN/10.1007/s11465-022-0711-5
https://academic.hep.com.cn/fme/EN/Y2022/V17/I4/55
Fig.1  Overall structure of the present work.
Fig.2  Machining-induced problems of thin-walled part (TWP). PCM: phase change material.
Fig.3  Narrow and broad fixtures for thin-walled part (TWP).
Category ICategory IICategory IIIRef.
Mechanical fixtureBF?Yan et al. [24], Qi et al. [25]
CFSingle-side CFAoyama and Kakinuma [26], Walczyk and Longtin [27], Li et al. [28]
Double-sides CFCraig et al. [29], Al-Habaibeh et al. [30]
Vacuum adsorption fixture (VAF)Sucker-based VAFHe et al. [31], Qi et al. [32], Liu et al. [33]
Hole-based VAFYang et al. [34]
Slot-based VAFRubio-Mateos et al. [35,36]
RFARTKihlman and Engstrom [37,38], Zhang et al. [39], Jonsson et al. [40]
MFCioat? et al. [41], Wang et al. [42], Croppi et al. [43], Nee et al. [44]
FUFMSBao et al. [45,46], Xiao et al. [47]
MRSVeeramani and Muthuswamy [48], de Leonardo et al. [49], Sagar et al. [50]
JSLiu et al. [51], Rajaratnam and Albers [52]
PCMAPCMIBFWang et al. [53], Liu et al. [22], Mironova et al. [5456]
PFZha et al. [57], Ge et al. [58], Gao et al. [59]
LMAWang et al. [20], Saito et al. [60], Lee et al. [6163]
PPCMMRF fixtureLiu et al. [64], Ma et al. [65]
IPBFLiu and Ke [66,67]
Mechanical-PCM composite fixtureMechanical-MRF composite fixture?Veeramani and Muthuswamy [48], de Leonardo et al. [49]
Mechanical-LMA composite fixture?Aoyama and Kakinuma [26], Al-Habaibeh et al. [30]
Tab.1  Fixture categories
Fig.4  Bespoke fixture for aircraft skin assembly and processing.
Fig.5  (a) Double-side CF [29], (b) single-side CF [26], (c) clamping function of double-side CF, and (d) support function of single-side CF. CF: conformable fixture. Reproduced with permissions from Refs. [26,29] from Elsevier.
Fig.6  Schematic diagram of the motion control mode of support pins: (a) PCM-based CF, (b) plate-based CF, and (c) motor-based CF.
Fig.7  Vacuum adsorption fixture (VAF) classification based on adsorption unit structure: (a) sucker-based VAF, (b) hole-based VAF, and (c) slot-based VAF. TWP: thin-walled part.
Fig.8  Schematic diagram of the overall structure of affordable reconfigurable tooling. Reproduced with permission from Ref. [39] from Elsevier.
Fig.9  MF classification based on fixation mode: (a) slot-based MF, (b) hole-based MF, (c) automatically adjustable MF, and (d) bespoke baseplate-based MF. MF: modular fixture. Reproduced with permissions from Refs. [42,78?80] from Elsevier and Taylor & Francis.
Fig.10  Follow-up fixture (FUF) classification based on support mode: (a) mirror support (MS), (b) multi-robot system (MRS) [48], and (c) jet support (JS) [51]. The supporting principle of FUF: (d) MS, (e) MRS, and (f) JS. Reproduced with permissions from Refs. [48,51] from Springer Nature.
Fig.11  Classification of support head based on movement mode: (a) sliding support head [47] and (b) rolling support head [92]. Reproduced with permissions from Refs. [47,92] from Springer Nature.
Fig.12  Differences between APCM and PPCM in terms of phase change properties. APCM: authentic phase change material, PCM: phase change material, PPCM: Pseudo phase change material.
Fig.13  (a) APCM clamping process for TWPs and (b) APCM types. APCM: authentic phase change material, TWP: thin-walled part, PF: paraffin fixture, LMA: low-melting alloy, IBF: ice-based fixture. Reproduced with permission from Ref. [20] from Springer Nature.
Fig.14  Structure and clamping principle of the pseudo phase change material fixture: (a) magnetorheological fluid (MRF) fixture, (b) electrorheological fluid (ERF) fixture [102], and (c) iron-powder-based fixture (IPBF). Reproduced with permission from Ref. [102] from Elsevier.
Fig.15  Mechanical-MRF composite fixture. PKM: parallel kinematic machine. Reproduced with permission from Ref. [49] from Elsevier.
Fig.16  “N-2-1” location strategy for thin-walled part.
Fig.17  Common location methods for thin-walled part (TWP) processing: (a) support rod/pin, (b) strong rigid suck, (c) weak rigid suck, (d) bespoke mould, (e) locator, (f) block, (g) platform, and (h) bolting.
Fig.18  Schematic diagram of the clamping mode of thin-walled part (TWP): (a) clamping device, (b) bolt, (c) VAF, and (d) PCM fixture. PCM: phase change material, VAF: vacuum adsorption fixture.
Fig.19  Schematic diagram of the suppression process of support force on machining deformation: (a) no machining, no support, (b) machining without support, and (c) machining with support.
Fig.20  Schematic diagram of support density: (a) discrete points, (b) array points, (c) local multi points, and (d) whole face. TWP: thin-walled part.
Fig.21  Schematic diagram of the fixture layout optimization process.
Fig.22  (a) Optimization of the fixture layout to suppress vibration and (b) optimization of the support force to suppress vibration. Reproduced with permission from Ref. [159] from Elsevier.
Fig.23  Damping method for the processing of thin-walled part: (a) particle-based damping (PBD), (b) tuned mass damping (TMD) [165], and (c) eddy current damping (ECD) [166]. Principle of damping: (d) PBD, (e) TMD, and (f) ECD. MRF: magnetorheological fluid, ECD: eddy current damping. Reproduced with permissions from Refs. [165,166] from Elsevier and Taylor & Francis.
Fig.24  Fixture layout mode: (a) fluid layout [174], (b) fixture unit layout [32], and (c) frame layout [39]. Principle of fixture layout: (d) fluid layout, (e) fixture unit layout, and (f) frame layout. MRF: magnetorheological fluid. Reproduced with permissions from Refs. [32,39,174] from Elsevier.
Fig.25  Adaptive adjustment of fixture-induced force. TWP: thin-walled part.
Fig.26  Intelligent fixture system operation process. PSA: particle swarm algorithm, GA: genetic algorithm.
Fig.27  Clamping protection for thin-walled part: (a) rubber and (b) ice-based fixture (IBF).
Fig.28  TWP fixture with a cooling function: (a) ice-based fixture (IBF) [22] and (b) jet support (JS) [51]; cooling principle: (c) IBF and (d) JS. TWP: thin-walled part, LN2: liquid nitrogen. Reproduced with permissions from Refs. [22,51] from Springer Nature.
Fig.29  Evaluation of thin-walled part (TWP) fixture functions.
ACAAnt colony algorithm
AFAdsorption fixture
APCMAuthentic phase change material
ARTAffordable reconfigurable tooling
BFBespoke fixture
CFConformable fixture
DOFDegree of freedom
ECDEddy current damping
ERFElectrorheological fluid
FEAFinite element analysis
FMSFFlexible multi-point support fixture
FPAFlower pollination algorithm
FUFFollow-up fixture
GAGenetic algorithm
IBFIce-based fixture
IPBFIron-powder-based fixture
JSJet support
LMALow-melting alloy
LN2Liquid nitrogen
MFModular fixture
MRFMagnetorheological fluid
MRSMulti-robot system
MSMirror support
NNANeural network algorithm
PBDParticle-based damping
PCMPhase change material
PFParaffin fixture
PFBParticulate fluidized bed
PPCMPseudo phase change material
PSAParticle swarm algorithm
RFReconfigurable fixture
RFPEReference free part encapsulation
TMDTuned mass damping
TWPThin-walled part
VAFVacuum adsorption fixture
  
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