BULETINUL INSTITUTULUI POLITEHNIC DIN IASI

Publicat de
Universitatea Tehnica Gh.Asachi, Iasi
Tomul XLVII (LI), Supliment, 2001
Sectia
CONSTRUCTII DE MASINI







APPLICATION OF MODULAR FIXTURING FOR FMS


BY


LIVIU SEGAL, CAMELIA ROMANESCU and
NICOLAE GOJINETCHI


Abstract: Modular fixtures are the most widely used flexible fixtures in
industry. They have gained an important role in the modern manufacturing
environment because they can reduce the time and cost required to design and
fabricate special-purpose fixtures and reduce the time and cost associated with
storing and retrieving the fixtures between different machining operations.
This paper presents some basic aspects concerning evaluation of modular
fixture systems for machining processes.

Key words: modular fixture, design, CAD.


1. Introduction

Flexible fixturing has become an important component of flexible
manufacturing systems (FMS) and computer-integrated manufacturing systems
(CIMS). There are several different categories of flexible fixtures, but modular
fixtures are most widely used in industry for job and batch production. The
flexibility of the modular fixtures is derived from the large number of fixture
configurations from different combinations of the fixture element. Modular fixture
elements can be dis-assembled after processing a batch of parts and re-used for
new parts. Figure 1 shows the application cycle of modular fixtures.
Liviu Segal et al. Constructii 158
Modular fixtures consist of a
set of standard components that
provide the fixture functions of
supports, locators, clamps and
fixture body. Fixture elements can
be categorised as vertical and
horizontal locating / clamping
elements, which are used to
support, locate and clamp the
workpiece. The modular fixturing
components are generally built
over a baseplate which can be fixed onto machine table, to create a fixture
capable of handling a wide variety of part sizes and shapes. Modular fixture
elements can be re-used for other parts once disassembled and they are
manufactured with high tolerances.
Commercially available modular fixturing systems can be classified into two
types: slot and hole-based systems. Slot-based modular fixtures have parallel and
perpendicular T-slots on the baseplates (Fig. 2a). Hole-based modular fixtures
have accurately positioned holes on the baseplates (Fig. 2b).


Fig. 2 - T-slot -and hole-based modular fixture baseplates

The main limitation of these modular fixtures, remains the time required for
designing the fixtures and assembling the modules.

2. Modular Fixtures Configuration Design

Traditionally the modular fixture design and assembly consists of the manual
selection of elements largely based upon all the information in regard to the
product and production process provided by the designer and manufacturing
engineer.
Modular fixture design adheres to two basic procedures [1]. First, the
functions and shapes of modular elements are defined, and the complete
versatility of each element is explored. Second, the right modular elements are

Component
Library
Fixture design
and assembly
Disassembly
fixture
Apply to
production
Fig. 1 - The usage cycle of modular fixtures
Comment:
de Masini Bul. Inst. Polit. Iasi, t. XLVII (LI), Supliment 2001 159
selected based upon their geometrical and topological characteristics and specific
functions for the fixture assembly. The criteria for component selection include
the simplicity for the fixture design, the complete restriction of the workpiece,
the preventing of workpiece bending and cutter collision, the ease of
loading/unloading and setting-up and the machining accuracy. A comprehensive
fixture is constructed by using selected components at the right locations, based
upon the basic fixture-design principles.



Fig. 3 - T-slot- and hole -based modular fixture set-ups example

The process of the T-slot-based modular fixture configuration design is a
highly experienced based process, in which fixture components are selected and
assembled into a functional structure with a certain sequence where manu-
facturing knowledge, experience and skill are required (figure 3a).





Fig. 4 - A modular fixture assembly configuration design process

The process of hole-based modular fixture configuration design is similar to
the process of T-slot modular fixtures design, but it is simplified because it
involves fewer types of fixture elements, fewer choices of hole alignment and
fewer position adjustment between components (figure 3b). Figure 4 shows the
simplified modular fixture assembly procedure.


3. Building Modular Setups and Documentation
Part design
review
Locating datum
selection
Component selection
and placement
Fastening
Testing
Part design
Process plan
Liviu Segal et al. Constructii 160

The tool design process for modular fixtures is basically the same as for
conventional fixtures, with a few differences. There are generally three ways to
design a modular fixture [5]:
- designing by actually building the fixture;
- preparing manual drawings;
- using a CAD system.
The first method is possible because modular fixture require only assembly
of modular components, not machining. Thus, once designers have a rough
design concept in mind, can build the fixture around a sample part. Simply place
the sample part on the baseplate and add locators and clamps as needed.
The second method, can be speeded up by using tracing templates. Thus,
when no sample part is available, the fixture can be assembled around a template
of the part. Templates are also useful to check for interference that could occur
when loading/unloading the part.
The third method is the most effective means for modular fixture design. A
database representing all elements of the modular fixture system in either 2D or
3D is created by the user using a commercially CAD system.




Fig. 5 - User interface for modular fixture assembly design
Thus, a user interface for interactively modular fixtures assembly design was
maked by authors, using AutoCAD solid modeller and Blco Technik modular

de Masini Bul. Inst. Polit. Iasi, t. XLVII (LI), Supliment 2001 161
fixture system. Furthermore, an assembly sequence file will record the elements
position and orientation on the baseplate.
In order to make the element selection, the interface provides, on-line
graphic icon menus to display the fixture components on screen according to their
categories. Figure 5 shows the user interface with the first menu of locators.
As application, figure 6 shown a design example of a modular fixture for
machining a virtual part in a horizontal milling machine. With an interactive CAD
system the usual sequence of design is to first put the workpiece on the screen.
The appropriate baseplate is then positioned under the part. Next, the designer
selects the necessary components needed to support, locate and clamp the part
from the component database. Finally, is generated the assembly sequence file.
The menu system provides an organisation of the fixture component
database with a visible display, which actually drives the sequence of fixture
component selection. When an element is selected, it is inserted into system and
needs to be placed into a proper position.
Fig. 6 - An example of a modular fixture design for the left workpiece

Using a CAD system to perform a modular fixture design, not only reduces
the time required for the design, but also allows the designer the freedom to
experiment several design alternatives before arrive to an optimal solution.
Moreover, in the process of design automation, CAD technology plays an
essential role in modeling the fixtures geometrically and rendering the design
solution graphically as is shown in figure 6.

4. Concluding Remarks

Liviu Segal et al. Constructii 162
By using flexible fixtures and automating the modular fixture design process,
many of the problems of poor reconfigurability inherent in the present generation
of FMS can be solved. The traditional modular fixture design and assembly
process can be greatly improved by using the CAD approach. Its interactive
nature provides the capability and flexibility for fixture designers to design
modular fixtures from a modular fixture system catalogue database. The graphical
user interface developed in this paper, can be similarly applied to other CAD
systems and for different modular fixture systems.


Technical University Gh.Asachi, Jassy
Department of Engineering Graphics


R E F E R E N C E S

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Journal of Adv. Manufacturing Technology, 5, 3, pp. 240-255 (1990).
2. G r i p p o P. M., G a n d h i M. V., T h o m p s o n B. S., The CAD of modular fixturing
systems. The Int. Journal of Adv. Manufacturing Technology, 2, 2, pp. 75-88 (1987).
3. W h y b r e w K., N g o i B. K. A., Computer-aided design of modular fixture assembly.
The Int. Journal of Adv. Manufacturing Technology, 7, 5, pp. 267-276 (1992).
4. M a W., L e i Z., R o n g Y., Fix-Des: a computer-aided modular fixture configuration
design system. Int. Journal of Adv. Manufacturing Technology, 14, pp. 21-32 (1998).
5.
*

*

*
Modular Fixturing Handbook, Carr Lane Mfg. Co., 1991.
6.
*

*

*
Blco Technik - Modular Fixturing System, Parts Catalogue, Blumle KG, Germany,
1998.


APLICAREA DISPOZITIVELOR DIN ELEMENTE MODULATE
N SISTEME FLEXIBILE DE PRELUCRARE

(Rezumat)

Dispozitivele din elemente modulate (DEM) sunt cele mai folosite dispozitive flexibile
din industrie. Ele si-au cstigat un rol important n cadrul fabricatiei moderne, deoarece
folosirea lor duce la reducerea timpului si costurilor cu proiectarea si fabricarea unor
dispozitive speciale nedemontabile. Totodata, folosirea DEM implica reducerea timpului si
costurilor asociate cu depozitarea si regasirea dispozitivelor ntre diferite operatii de prelucrare.
Lucrarea prezinta cteva dintre aspectele de baza privind evaluarea sistemelor de
dispozitive modulate pentru operatii de prelucrare.