Analysis and synthesis of fixturing dynamic stability in machining accounting for material removal effect

A machining fixture is a critical link in a machining system as it directly affects the operational safety and part quality. The design of a machining fixture must enable the workpiece to remain stable throughout the machining process. Numerous efforts have been made in the past in modeling, analysis, and synthesis of machining fixture-workpiece systems. The majority of prior work treats the fixture-workpiece system as quasi-static and ignores the system dynamics. In addition, the material removal effect on fixture-workpiece system properties and behavior is generally ignored.; The primary goal of this thesis is to develop a model-based framework for analysis and synthesis of the dynamic performance, emphasizing fixturing dynamic stability, of a machining fixture-workpiece system accounting for the material removal effect. The five major accomplishments of this thesis are as follows.; First, a systematic procedure for analysis of fixturing dynamic stability of an arbitrarily configured machining fixture-workpiece system is developed with consideration of the effect of material removal on fixture-workpiece dynamics.; Second, models and approaches for simulation of fixture-workpiece dynamics and analysis of fixturing dynamic stability are experimentally validated. Good agreement between model outputs and measurements is found. It is concluded that consideration of dynamics and characterization of system dynamic properties are crucial for an accurate analysis of the machining fixture-workpiece system.; Third, an in-depth theoretical and experimental investigation of the material removal effect on fixture-workpiece dynamics is performed. The results show that the dynamic behavior and properties of the fixture-workpiece system change substantially when a significant portion of material is removed. Approaches developed in this thesis are shown to be capable of capturing the effect of material removal.; Fourth, the roles of important fixture design and machining process parameters in affecting the fixturing dynamic stability are studied and understood via a parameter effect analysis. Certain parameters are found to have a more pronounced impact on fixture-workpiece dynamics than others. Additionally, the fixturing dynamic stability is found to be sensitive to the parameter imprecision.; Finally, a generic approach for the determination of the minimum clamping forces that ensure fixturing dynamic stability in machining is developed. Because of the material removal effect, dynamic clamping is found to be an option to achieve the best possible performance of the system.; Models and approaches developed in this thesis are generic and can be used as simulation tools in fixture design. Insights obtained from this research will advance the fixturing knowledge base and provide general fixture design guidelines.