unification, standardization and automation of fixture design.

A few years ago, after understanding the significance of the problem of computer aided fixture design, the Institute for Production Engineering, Faculty of Technical Sciences in Novi Sad, began the development of automated fixture design system. The paper presents the results of the conducted researches.

2. FIXTURE DESIGN AUTOMATION

In modern production systems with automated production and automated product design, there appears an imposed requirement to design fixtures with the aid of computers. When designing fixtures manually, most of the time and the adjoining basic costs go to the following: elaboration of the general construction aspect, detailed construction elaboration, searching for necessary information on the existing fixture solutions, or fixture elements, and the like. All the other activities require noticeably shorter working time and costs. These are, before others: introduction to the design task, performing necessary calculations, composing the BOM, control, etc. Therefore, it is appropriate to automate at least those functions whose realization requires more time, and subsequently more adjoining costs. These researches imposed a need for introducing new technologies into fixture design process, which are based on the so-called flexible automation, and whose main objective is to shorten time and decrease costs when designing new fixture constructions and re-use the existing solutions with or without modification. The automation of fixture design process is successfully solved by applying the system for Computer Aided Fixture Design (CAFD). The first attempts of fixture design automation go back to the 1990s and originating as the cause-effect answer to the negative aspects of classic design methods. This aspect of fixture design implies the use of a computer that, partially or completely, automates the sequences of fixture design. The goal is to generate adequate fixture within the acceptable time period and to reduce the designers subjective influence to the minimum. The most important assumptions for computer application in fixture design process are the following: translating the designers knowledge and experience onto the language that is understandable to the computer, the development of selection and decision-making logics, etc.

COMPUTER AIDED FIXTURES DESIGN

Djordje VUKELIC Janko HODOLIC Abstract: Researching the possibilities for fixture design aided by computers has been in the sphere of interest of a number of authors worldwide for a longer period. Research results have led to the precise and systematised knowledge on the possibilities offered by computer application in fixture design process. The paper emphasises the importance of fixture design automation. It presents a general structure of the automated design system with a special highlight on the fixture design systems and their main characteristics. It also shows a structure and a part of output results of the automated modular fixture design system. Finally, the reached conclusions are presented with the expected directions of future researches. Key words: CAFD, fixture, automated design

1. INTRODUCTION
Current production systems in manufacturing industry are characterized by product range extension, high frequency in changing production programs, demands for constant product quality improvement, shortenings in production time, constant need for increasing technological level of products and decreasing their manufacturing costs. With such market demands, and intensive development of science, technique and information technologies, the level and the trend of further development of technological machining processes in metal manufacturing industry depend on all the composing factors, those being the following: type of blank, machining process, order of operations, machinery, operation and sequence concentration, tools, fixtures, measurements, etc. In order to raise technological solutions to a higher level, it is necessary to solve optimally all these elements. Fixture selection and design takes a significant part of the total time necessary for technical and technological production preparation. To shorten that time means also to decrease the adjoining costs. It can be done, among other things, by applying new methods in fixture design. These new methods are based on classification,

Fig.1. Fixtures designed using computer (Bluco Corporation Naperville) 21

In basic, automated design systems are the systems founded on the application of modern information technology, and by their structure and functioning, they present special-purpose modern information systems. Accordingly, and in compliance with the natural demand for information unity within a production system, there has been a possibility and a need for design aided information systems to functionally and substantially integrate into the appropriate systems of other business functions in order to increase system efficiency in total. Considering the structural and functional organization of the automated design system, as well as all its properties, it could be said that all automated design systems are characterised by the existence of six fundamental construction elements: technical basis, database, software system, human resources for the development, exploitation and maintenance of the system in function, input information, output information. The general structure of the automated fixture design system can be shown with the following picture (Figure 2.).

Database makes the basis of the software system. Its main purpose is to ensure the efficiency of the automated design system in the sense of qualitative and effective performance of the database main functions. Those refer primarily to data acquisition, memorizing, keeping, searching and updating. The base contains graphic, textual, numerical, mathematical, logical and other necessary data. These data are connected to workpieces, fixture elements and final fixture constructions. R&D, exploitation and maintenance of the system in function are made of a group of people. Part of the team develops the automated design system, part of it exploits it, and a part keeps it functioning. Very often, their domains overlap. Sometimes, one person can do all three functions. Input information in the automated fixture design systems can be divided into three larger groups: constructive information on a workpiece, technological information and information concerning production organization and management. Output information is the system output. They are adapted to the needs of individual users. Important output information are fixture engineering drawing and fixture assembly drawing. Often, it is necessary to provide workshop drawings for the parts, and less often, among other thing: weights of individual fixture elements, fixture total weight, fixture price, storage place, etc.

3. SYSTEM STRUCTURE
Having in mind the trends concerning the development and computer usage in the manufacturing industry, especially in the segment of applying CAx technologies when designing fixtures, the model of this system is based on the modular principle. Automated fixture design system is founded on the methods for selecting, modifying and designing new fixture constructions. On one side, it is intended for fixture design, and on the other, it is based on modular principle and interactive work. Main system structure comprises six segments (Figure 3), those being the following: 1. Input data module, enabling the input of all necessary information important for fixture design; 2. Solution fixture module, enabling fixture selection from a database provided it contains a working solution; 3. Modification fixture module, enabling the modification of the existing fixture constructions in order to acquire the necessary one; 4. Design fixture module, enabling the design of new fixture construction; 5. Output data module, enabling the definition of output information from the system; 6. Data base module. In addition, in the complex software system model for automated modular fixture design, the stress is especially given to the presence of: computer system as a technical basis, CAD software system with universal (general) application, and person designer and their interactive work with the computer.

Fig.2. General model of the automated fixture design system The term technical basis refers to the available hardware necessary for successful program functioning. The most important requirements placed in front of the technical support are: faster work speed, large memory capacity, quality, reliability, etc. Software system of the automated fixture design system, as for automated design in general, contains two segments: operative software system and applicative software system. Operative software system implies all those software having the purpose of letting and managing the work of technical basis, as well as its keeping in function. Applicative software system is used for solving certain tasks. Applicative software is either bought as a final product or individually developed (programmed) one and it is used for a certain design job requirements by the user. 22

Based on input information necessary for fixture design, in general case, the selection of the existing fixture can be performed, if need be further developed, and if such solution does not exist, new fixture can be designed. Database can hold records of fixture solutions which can be appropriately marked. Fixture solutions with different degree of operative usability will be acquired on the fixture selection level. If there are several fixture solutions, techno-economic analysis serves to find the most satisfactory solution for the case in question. If the solution that cannot be directly applied is gained at the fixture design level, the fixture is modified. There is a possibility not to acquire fixture solution at all. What follows is a synthesis of a new fixture construction. In that case, it is justifiable to divide the fixture into certain functional segments and design fixtures in phases. In the end, it is necessary to shape the fixture and generate fundamental technical documentation.

3.1. Fixture homology

Fixture homology presents a complex of measures for rational reduction of construction types and dimensions. The principle of fixture construction homology following the schemes base construction, type construction, work construction and adjustable and/or alternating elements is acceptable for all fixture classes. Fig.4., as an example, presents the phases of constructive modular fixture homology.

Fig.4. Phases of constructive fixture homology Base construction presents a universal structure, i.e., a group of elements with multifunctional usage in fixture construction of several types and dimensions. Base constructions are the forms of fixture construction that have similar locating scheme and geometric shape as a workpiece. Type construction is a constructional fixture scheme made on the basis of basic construction and containing primarily principal type elements for locating and clamping workpieces of certain types. Type fixture constructions have similar process characteristics, clamping scheme, locating scheme and geometric characteristics to workpieces for which they can be used. Work fixture construction presents a set of principal or type constructions and a group of alternating and/or adjustable elements in coordination with concrete machining operation. Work construction presents final fixture construction applied at the working place during machining process.

Fig.3. General structure of the automated fixture design system For the previous activities to be performed successfully, it is essential to systemize principal bases for fixture design, make a database, develop the program systems for automated fixture selection, modification and design, and select adequate program and technical support. Systematization of the principal bases creates the assumption for setting detailed concept and development of the automated fixture design system. Principal bases are the following: fixture homologize, classification of elements and final constructive fixture solutions, criteria for element selection and adequate logic for making decisions while designing.

3.2. Fixture classification

Classification mode of fixture description enables alphanumerical description of all fixtures based on fixture properties systematization. Classification process can simply be described as division of a basic set to subsets according to certain characteristics. Fixture classification links same and similar fixtures. The usage of fixture classifiers can lead to final fixture solutions or to partial fixture solutions whose parts can directly be used for a new construction. Classification is done by technological and constructive fixture characteristics. In the process, the necessary information is gained by linking certain codes 23

or code combinations to certain fixture parameters. The features considered for classification are the following: qualitative machining type, location scheme, clamping scheme, etc, quantitative workpiece dimensions, number of simultaneously machined workpieces, clamping force intensity, etc. The structure of the fixture classifier (classification code) shown in Fig. 5. Classification code is divided in to four parts. Parts of classifier are made from specific marks wich are represented with code numbers. Every part of fixture classifier can be refered in separate or integated. Information about: manufacturing characteristics (part 1), workpiece characteristics (part 2), locating characteristics (part 3) and clamping characteristics (part 4), can be found in parts of fixture classifier.

in question. They are entered on the basis of workpiece drawings, technological machining procedure (operation cards) and additional necessary information (clamping force intensity, clamping power, etc.). Input information is used to define classification code of necessary fixtures using classifiers. A segment of the developed classifier is presented in Fig. 7.

Figure 7. Segment of the fixture classifier After the input of all necessary information (characteristics) within each classifier block is performed, necessary classification code for the necessary fixture solution is generated (Fig. 8). Fig.5. Fixture classifier

3.3. Criteria and logic for selecting fixture elements

Based on systematization and analyses, a criterion and selecting logic is defined for every fixture element. Then, database of fixture elements is searched for finding the solutions that satisfy certain criteria. Criteria and decision logic are crucial for efficient system application, since they make possible the selection of adequate constructive elements from all fixture functional groups for certain workpiece and certain machining operation. An example of decision making for selecting one location element is shown in Fig. 6. Fig.8. Classification code for the necessary fixture With the defined classification code, next step is to enter the subsystem for fixture selection and search the database of finished constructive fixture solution within the developed database. The correspondence degree is determined between the necessary classification code of the necessary fixture and the existing one. All characteristic constructive fixture solutions (working and/or type) are filtered (if they do exist) and presented on a special form (Fig. 9.). The order for showing characteristic solutions in the determined fields is defined by techno-economic optimization, from the best to the worst.

Fig. 6. An example of criteria for selecting location elements of modular fixtures

4. SYSTEM FUNCTIONING
Input information contains data for computer processing within all modules of the automated fixture design system 24 Fig. 9. Form with the survey of possible constructive fixture solutions

The existence of working solution (Fig. 10.) finishes the design process, and the necessary technical documentation is acquired by moving from the subsystem for fixture selection to output data module, where the fixture report generating is performed.

the movement to the subsystem for fixture design. In this case the search through fixture elements database is performed, followed by the selection of all necessary elements within certain functional groups. Element selection is done, similar as in fixture modification module, on the basis of particular properties within classification mark of the necessary fixture, since it contains search criteria. Separating certain solutions is performed with the help of the selection logic contained in the program code. Insight into all the possible generated fixture elements solutions is done with the form where the functional group of elements whose survey one would like to see can be chosen (Fig. 12.). It is possible to obtain a larger number of elements that satisfy the set criteria and perform the same function. In that case, the designer by their own free will chooses one or a few of them.

Fig. 10. Presentation of the form for fixture survey If data base contains type solution for the fixture, by selecting one of them and continuing the design process, the designer opens the form (Fig. 11.) with the survey of the elements that should be added in relation to the existing construction, as well as the list of elements that should be altered and/or adjusted in relation to the existing solution.

Fig. 12. Form with the survey of possible fixture elements for workpiece positioning Since the designer at this design stage has selected fixture elements, the next step leads to output data module to perform fixture generating. Necessary elements are entered gradually, one by one, for better survey and possible collision avoidance (Fig. 13.). First, the workpiece is entered, then positioning elements, then for clamping, and so on, following the concrete needs. It is advisable to arrange each element immediately after the entrance around the workpiece model to the certain place using certain limitations (perpendicularity, symmetry, tangency, parallelism, etc), as well as basic functions of object manipulation translation and rotation. It is also possible to form one or more subassembly and their mutual entrance.

Fig. 11. Form with the survey of fixture elements for modular fixture modification The list of elements is formed on the basis of the classification mark of the necessary fixture that was generated within input data module, and the developed decision-making logic for selecting each element from particular functional groups. Classification mark, that is its particular properties, carries appropriate information selection criteria. These criteria serve to select fixture elements on one side, and type solution for the fixture on the other. On the exit from the subsystem for fixture modification, the adequate type solution for the fixture and adequate modification elements are acquired, and they are then entered into the output data module to perform necessary corrections. The absence of all three characteristic fixture solutions in the database demands

Fig. 13. Characteristic steps in fixture design 25

After modular fixture joining has been performed, there comes construction analysis, and if the gained solution is satisfactory, the fixture is archived into the database in an automated cycle, so it could be used later if there appears the need for it. Output information contains all the important data for successful fixture installation and exploitation. Output information is placed in fixture reports (Fig. 14.).

structure analysis (FEM analysis), to manufacturing simulation and NC code generating. The developed system for automated modular fixture design presents an efficient way to come to adequate fixture solutions in current manufacturing. For wider application of the developed system, further extensive activities are necessary to upgrade database with the significant number of reliable information bases. Furthermore, it is necessary to improve the existing segments within already developed system structure and to work on bringing them to practical application in the sense of potential adaptation to a concrete production system. The degree of system efficiency can be increased if the system is integrally connected to any of the systems for CAPP and systems for CAE. Further research should be directed to the development of intelligent behavior of this system as well.

REFERENCES
[1.] BI, Z. M., ZHANG, W. J.: Flexible fixture design and automation: Review, issues and future directions, International Journal of Production Research, 2001, Vol. 39, No. 13, pp. 2867-2894. [2.] BLUCO CORPORATION, Naperville, Product Range, from http://www.bluco.com, accessed on 1307-2006. [3.] CAMPBELL, P.: Basic Fixture Design, Industrial Press Inc., 1994, ISBN 0831130520. [4.] CECIL, J.: Computer Aided Fixture Design - A Review and Future Trends, The International Journal of Advanced Manufacturing Technology, Vol. 18, No. 11, 2001, pp 790 - 793. [5.] HALDER NORM TECHNIK, Erwin Halder KG, Product Range, from http://www.halder.de, accessed on 20-07-2005. [6.] KRSMANOVIC, C.: Automation design in Industrial Engineering, Faculty of Technical Sciences - Institute of Industrial Engineering, 2003. [7.] RONG, Y., ZHU, Y.: Computer Aided Fixtures Design, Marcel Dekker, 1999, ISBN 0824799615 [8.] RONG, Y., HUANG, S. H.: Advanced Computeraided Fixture Design, Academic Pr, 2005, ISBN 0125947518

Fig. 14. System output result

5. CONCLUSION
Based on previously conducted analyses, literature information and contacts with the scientists and experts in the field in question, it can be concluded that completing technological machining processes with fixtures is one of more significant and complex tasks. Therefore, a lot of research organizations, institutes and universities pay special attention to CAFD system development. The developed software solution for the automated modular fixture design completely satisfies set requirements. Design process has been significantly accelerated, and the degree of fixture solution typification and unification has increased, which advantages to the rationalization of the design process and all the other processes succeeding as its consequence. It enables designing that is more rational by creating symbiotic type assembly, as well as efficient model generating through parameter independent construction elements. Due to the fact that all models are contained in one database, the compactness is gained and the possibility of losing some models is prevented, while the solution openness for expansion and supplements has been ensured, both on the group level and within types. Since the solution has been realized within the software system Pro/ENGINEER, the obtained models can efficiently be used in other modules for designing technological manufacturing processes, beginning with generating technical documentation, via 26

CORRESPONDENCE
Djordje VUKELIC, M. Sc. Eng. University of Novi sad Faculty of Technical Sciences Trg Dositeja Obradovica 6 21000 Novi Sad, Serbia vukelic@uns.ns.ac.yu Janko HODOLI, Prof. D.Sc. Eng. University of Novi sad Faculty of Technical Sciences Trg Dositeja Obradovica 6 21000 Novi Sad, Serbia hodolic@uns.ns.ac.yu