ENS6126 Master of Engineering 1

Progress Report

CAD BASED DESIGN OF WELDING FIXTURES

Achyut Kumar Reddy Tirupari

Student # 10339119

24 Oct 2016

Supervisor: Dr Majid Rad

 Abstract

Computer-aided fixture design has been existent for a very long period, but are
functional only for machining purposes neglecting the welding fixtures. Welding fixture has
also been less focused till date. It helps in avoiding welding distortion.

Design of modular welding fixtures and assembly of their parts are complicated by the
reason of various parts involved in its comprehensive structure. A result for this is building
a CAD based 3D modelling and simulation system to calculate the type of fixture elements
and array of assembly. The methodology for the computer-aided welding fixture design
framework is created. Modular welding fixtures make use of easily changeable parts or
components like welding table, clamps and also locators. These parts are assembled and
also dismantled where ever we desire, for a welding operation.

A welding fixture element database is developed and the fixture elements are divided into
various sections relying upon geometries and functions. Based on the information of the
user rules are developed and the rules will help in determining the fixture elements and
locations. Flowcharts are developed by connecting the inputs with the constructed rules..
The flow charts exhibits the information of the fixture pattern. In the final stage we make
use of Driveworks Express an extension of Solidworks software for automation purposes.

i
Contents
1 Introduction................................................................................................................................ 1
1.1 General..................................................................................................................................... 1
1.2 Objectives................................................................................................................................. 3
1.3 Significance............................................................................................................................... 3
1.4 Report Organization................................................................................................................. 4
2 Literature Review............................................................................................................................ 4
2.1 CAFD Process Requirements............................................................................................... 5
2.2 Fixture Design..................................................................................................................... 6
2.2.1....................................................................................................................Set up Planning
........................................................................................................................................... 7
2.2.2...................................................................................................................Fixture planning
........................................................................................................................................... 8
2.2.3...........................................................................................................................Unit design
........................................................................................................................................... 8
2.2.4...........................................................................................................................Verification
........................................................................................................................................... 8
2.3 CAFDV shares information between Technical Design Engineers and supply Chain
managers........................................................................................................................................ 9
2.4 Specific to Welding fixtures.............................................................................................. 10
2.5 Research in early 2000s.................................................................................................... 11
2.6 Applications of modular fixtures and dedicated fixtures.................................................. 13
2.7 Welding Fixtures............................................................................................................... 14
2.8 Modular Welding Fixtures................................................................................................ 15
2.9 Flexibility in manufacturing.............................................................................................. 16
2.10 Modern day research concentrates on modular fixtures as well...................................... 18
2.11 Case Based Reasoning (CBR)............................................................................................. 19
2.12 Rule based fixturing system.................................................................................................. 20
2.12.1 Database........................................................................................................................ 20
2.12.2 Rules.............................................................................................................................. 20
2.12.3 Control Strategy............................................................................................................ 21
2.13 Automation of the Clamping design process.................................................................... 21
2.14 Fixture Design Analysis..................................................................................................... 22
3.0 Proposed Approach.................................................................................................................... 23
4.1 preliminary result and discussion............................................................................................... 24
4.2 Creation of design library....................................................................................................... 24
4.3 Rules for the selection of modular welding fixture components............................................26
4.3.1 Welding table selection.................................................................................................... 26
4.3.2 Locating principles for selection of components............................................................. 30
4.3.3 Clamping rules for the selection of components.............................................................. 32
5 Conclusion & Future Work....................................................................................................... 34
5.1 Conclusion.............................................................................................................................. 34
5.2 Future work............................................................................................................................ 34
References........................................................................................................................................ 35
6. O Appendices............................................................................................................................... 37
6.1 Welding Table specifications................................................................................................... 37
6.1.1 Welding Table with 1150mm1160mm........................................................................... 37
6.1.2 Welding Table with 196mm01000mm........................................................................... 38
6.1.3 Welding Table with 2960mm1000mm........................................................................... 39
6.2 Clamps.................................................................................................................................... 40
6.2.1 Mag spring Clamp........................................................................................................... 40
6.2.2 Table mount C-clamp...................................................................................................... 41
6.2.3 Round Stock Pliers.......................................................................................................... 42
6.3 Locators.................................................................................................................................. 43
6.3.1 V-block............................................................................................................................ 43
6.3.2 Support............................................................................................................................ 44
6.4 Fixture Assembly.................................................................................................................... 45

List of Figures

Figure 1 Fixture Design Steps Source: (Kang Y., 2003)........................................................................ 7

Figure 2 Automotive related stud weld fixtures on a trunion frame (DBM Innovation, 2016).........11
Figure 3 Robot weld fixture Source: (Hui Wanga, 2010)................................................................... 12
Figure 4 Pin Array Application Source: (Hui Wanga, 2010)............................................................... 12
Figure 5 A typical CAFD for Welding Fixtures Source: (Y. Rong, 2016)..............................................13
Figure 6 Welding positioner Source: (Prof. S.N.Shinde, 2014).......................................................... 15
Figure 7 Modular fixture of a construction machinery part Source: (BLUCO Corporation, 2016) .. 16
Figure 8 Dedicated fixture for a construction machinery Source: (BLUCO Corporation, 2016)........17
Figure 9 Design library...................................................................................................................... 25
Figure 10 Fixture assembly in Solidworks......................................................................................... 26
Figure 11 Welding Table 1150mm 1160mm.................................................................................. 27
Figure 12 Welding Table 1960mm 1000mm.................................................................................. 29
Figure 13 Welding Table 2960mm 1000mm.................................................................................. 29
Figure 14 Welding Table 2600mm 1250mm.................................................................................. 30
List of Tables

Table 1 List of Components in Design Library................................................................................... 25

iv
1 Introduction

1.1 General

Fixture design is a process design activity which is of paramount importance. For this
reason, computerized automation is essential to integrate CAD and CAM. A literature
review of the state of the art trends and approaches for welding fixture design is
presented. Some shortcomings of the current approaches is also discussed and new
research focus areas are explored. A part that must be machined is held by an assembly
or a component. This assembly or component is called a fixture. It must be designed
properly so that it would fit the shape of the part and be compatible to the machining
process. This review would discuss the CAFD (Computer Aided Welding Fixture
Design) basics and techniques etc. and would also dwell on fixture planning, dedicated
or modular fixture design, verification of fixture design (CAFDV) and of course how all
these can be integrated with the main CAD/CAM process.

Production costs, time required for product development, time required for process
development are all significantly reduced by the proper utilization of CAFD tools. Not
only the above-mentioned benefits but also the simulation techniques that are involved
in CAFD give a boost to quality assurance of the final part. Moreover, it becomes easier
to make cost estimates for making business related quotations to customers, specifying
parameters as specifications for technical purposes as all these are required in the Supply
chain mechanisms prevalent in the business world (Huang, 2005).

This review considers the various steps that are required for welding fixture design. It
also presents the various important researches that have been conducted the world over,
and describes the requirements for welding fixtures that have developed over time.
Moreover, the paper also dwells on the most important and related research that has been
carried out in CAFD field which has utilized intelligent techniques and CAFD principles
that relate to this type of work. The review also presents the CBR approach (case based

1
reasoning). It has been considered as the most successful he most successful approach in
CAFD. The

2
presentation of this approach uses information on various applications, the different
stages of systems based on CBR fixture design. It also describes the work principles as
well as the relevant approaches that have been proposed. Also, the shortcomings in the
current methods is highlighted (Heidar Hashemi, 2016).

Computer technologies have caused a total revolution when it comes to the designing
and manufacturing of products these days. There are various CAD/CAM applications
and then for enterprises there are PDM/ERP (Product Data Management / Enterprise
Resource Planning) systems. Engineers get the tremendous benefit of creating
prototypes at an amazing pace and the CAFD platform enables them to depend on
human interaction to a minimum.

Fixture design engineers are the ones who utilize CAFD to its best. They generate
designs of fixtures. As technology is causing a higher level of integration on cross
border or cross platform basis, the Supply chain management can also join into this
integration of CAFD and SCM. The fixtures are sent by the Supply Chain Managers to
outside sources (vendors who run production lines) and conversely when they receive
the products, they would again use CAFD to inspect and conduct quality assurance
related research on these. More than one solution is normally outputted by an automated
fixture design system dependent on certain criteria which are pertinent to the design.
Therefore, the CAFD engineers have the luxury to choose the best alternative after
assessing the capabilities and advantages of each of the solution offered by the
automation. The engineers who have the required technical knowledge are better suited
to choose the best alternative as compared to Supply chain managers. This step is the
one that gives rise to the requirement of computer Aided Fixture design verification
application (CAFDV).

Connect with each other giving us tremendous benefits in relation to the use of computer
based methodologies. Many requirements on the manufacturer wish lists have already
been fulfilled. These include: lower development time, a tremendous improvement in
final quality, and last but not the least much lowered costs. This was achieved in the
CAD and CAM world by combining the fixture design knowledge with CAD platform
and applications. The result was CAFD.
1.2 Objectives

The primary objective of the project is to shorten the design time incurred in
designing a modular welding fixture
A design library is to be created to store numerous fixture elements with ease of
accessibility
A CAFD should be created to select the fixture components. For this purpose,
Rules are constructed depending on the information of the client.
Flow charts are built using the constructed rules. The inputs of the flow chart are
derived from the geometries of the workpiece.
To automate the assembly of the modular welding fixtures, a framework should
be created using the rules.

1.3 Significance

Production lead time is the main aspect that is to be considered because of their effects
on industrial growth. Modular welding fixture design consumes a lot of time to
construct. This CAD based design of modular welding fixture is a modern method of
designing in which time frame can be reduced by using the various fixture designs by
modifying the fixture design.

The 3D modelling methodology is a basic element in improving the relationship between

welding fixture components and work pieces in welding fixture design process.
Therefore, in this consideration Solidworks is applied a CAD software because of its
strong 3D modelling and assembly automation. (U.H., 2013)
1.4 Report Organization

This project is been divided into 5 chapters.

Chapter 1 provides the brief explanation about the introduction to the modular welding
fixtures and explains the objectives of the project

Chapter 2 explains about the early researches of the welding fixture design process,
fixture design and about the applications of the modular welding fixtures

Chapter 3 explains about the proposed approach and the objectives which are achieved

Chapter 4 explains about the creation of Solidworks design library and the rules created
to select the fixture components from the design library.

Chapter 5 explains about the Conclusion and the future work which should be achieved.

2 Literature Review

There is a need to hold the workpiece in place when an assembly operation or a

machining process is going on. The tools that hold the workpiece are called fixtures. To
produce consistently machined parts, the fixtures are extremely important. They also
ensure that parts produce do not vary from one to the other thus ensuring consistency in
quality and shape. Traditionally fixtures were dedicated as they were created exclusively
per workpiece to suit its requirements. However, this raises the cost to sky high
proportions as every workpiece requires a fixture. On the positive side, very high quality
and tolerance is possible with dedicated fixtures. Lately for many years, as flexible
manufacturing is in vogue, there was a need to create flexible thus modular fixtures
which could be adjusted for different workpieces. These fixtures adapt to the workpiece
requirement.

The general review is followed by specific Welding fixture related information. CAFD
has developed since the 1980s and a lot of work has already been done to improve the
fixture design process. The computerized environments present a virtual design
environment to the designers and thus they can try different techniques on trial and error
basis, identify probable problems, and experiment without the need to create a lot of
actual physical prototypes of fixtures that would have otherwise been required to
conduct tests for analysis purposes. The designer is also able to avoid many human
errors that can creep into the design process f designed manually. With the avoidance of
mistakes, a lot of time is saved (S., 2009).

2.1 CAFD Process Requirements

As the fixture design process proceeds, each step of the process requires several design
requirements to be considered. These could include such steps requirements as: Usability
requirements, Design constrains, Collision prevention, Tolerance requirements,
affordability requirements and other physical requirements (Heidar Hashemi, 2016).

Physical requirement

The fixture must be physically fit into the workspace geometry and its weight should be
accommodated. This is a physical requirement.

Collision prevention requirement

The tool path fixture, the fixture-fixture and the workplace place need to avoid collision
at all costs. This is a Collision prevention requirement.

Design constraining requirement

The stiffness of the workpiece and fixture, and the stability of the workpiece constitute
the Design constraining requirement.

Usability requirement

The weight of the fixture, chip shedding facilitation, surface damage avoidance etc.
would constitute the usability requirements.

Affordability requirement

The cost of the design process, operation and assembly time would constitute the
Affordability requirements.
Tolerance Requirements

The part design tolerances must be satisfied sufficiently by the fixture locating loading
tolerances. These are the tolerance requirements.

Conflict among requirements

Interestingly conflicts can arise among these requirements. An example can be e.g. It is
possible to get an advantage with a heavy fixture as it would be more stable. However,
this would be offset by the heavy cost incurred in making it thus affecting Affordability
requirements. Moreover, it might impede easy handling thus affecting usability
requirements (Boyle I., 2011).

2.2 Fixture Design

In general, it can be stated that there are 4 components in fixtures. These include: the
locator, the clamps, the support, and the base plate. Normally, designing a fixture would
involve the placement of different components inside a workpiece in such a way that
stability of the workpiece is guaranteed and that the components are immobile inside it
during the operations that would be required during machining or otherwise (Boyle,
2006).

Moreover, the number of steps that are involved in the fixture design process are also
four. These include the planning for the setup, planning for the fixture, design of the unit
and lastly verification. These are shown in Figure 1.
 Figure 1 Fixture Design Steps Source: (Kang Y., 2003).

2.2.1 Setup Planning

The function of setup planning contains producing a segment of the set of entire
manufacturing feature instances with the end goal that each segment can be machined in
a single setup. Furthermore, the array of operations inside each setup, as well as the
array of setups are resolved. For every setup, the fixture plan should be resolved,
guaranteeing that the planned fixture configuration will give a force conclusion on the
workpiece amid the machining operation. Another element of significance in setup
planning is the determination of tools which should be required to execute every
operation. Tool selection should be completed before the fixture plan is created, since the
covering of the tool path should not obstruct the planned fixture setup.
2.2.2 Fixture planning

The task is to produce a fixture assembly that gives appropriate part orientation,
location, supports and clamping with the end goal that all the objective components can
be machined. The initial phase in this procedure is to recognize the extensive
classification of fixturing technique that should be utilized such as modular fixturing,
vise fixturing and so on. Aside from constructing the planning task locally productive,
this may help in worldwide proficiency of setup planning if the knowledge of the past
setup can be utilized to diminish the quantity of components that change over setups.
The second phase is the development of the fixture assembly. This is finished by
evaluating the past geometry and determine the orientation at that point all mating
features on the part are resolved which might be utilized as a part of assembly. The
fusion of the fixture assembly can now continue utilizing the essential standards of
fixturing as rules for the location of fixturing points and investigation of the possible
freedom of motion of the various assembled components. Since the definite models of
the fixture components are accessible, every progression of the assembly can be
incrementally confirmed for appropriate position and feasibility. The extent of this work
has been restricted to consider that frictional contacts because of clamping and give
arbitrary (Joneja & Chang)

2.2.3 Unit design

It gives the details and concepts for the locating unit and the clamping units of the fixture
that is composed with the base plate.

2.2.4 Verification

Verification is about ensuring that the design of fixture that has been developed is
satisfying the fixturing requirements substantially.

There are other requirements that would be met as well e.g. cost of the fixture, its weight
and the time required for the assembly of the fixture (Huang, 2005).
As per the requirement of the design and process required for the part, the exact location
and the clamping of the workpiece are the main considerations of the Fixture planning. A
self-configured layout that gives a guarantee for the stability of the part is outputted by
this activity which is very much driven by the experience of the designer (Nelaturi S.,
2014).

Location accuracy is then achieved via the unit design step and so is the stiffness.
Avoidance of deformation of the fixture components is also a desired result in this step.
The accuracy of the location can only be reached if the locating units tolerances are
permissive. This way, clamping forces and the machining process is unable to cause any
unnecessary deformation. These are the necessary requirements on part of the design of
the clamping and machining units (Boyle, 2006).

2.3 CAFDV shares information between Technical Design Engineers and

supply Chain managers

The demand for CAFDV emanated from both the fixture design engineers and from
todays supply chain managers. Both, to co-ordinate with each other wanted a tool to
intimate them of the quality of a fixture design, and to also figure out any possibility of
probable problems well before the manufacturing phase is carried out. As far as the
supply chain managers are concerned, thanks to CAFDV, they now have the capability
to not just measure the product quality but also to control it. This is possible without the
Supply chain managers having any technical knowledge about verification or fixture
design (Kang, 2001).

CAFDV utilizes two types of designs; models; the geometric model and the kinetic
model. These are used for representing, verifying and optimizing designs of fixtures. The
former makes use of the Jacobian Matrix which it uses to establish a relationship
between the displacements of workpiece and fixture. The kinetic model on the other
hand utilizes the Fixture Stiffness Matrix. It links fixture deformation with external
forces and the same linkage is established for workpiece displacement and the external
forces. Computer software for CAFDV is also provided by engineering software
developers. These are fully integrated with 3D CAD applications. Both CAD integration
and a user-friendly GUI are available from these developers. These software packages
allow the technical user to
conduct checks on the fixture and get visual results and well as analytical results. (Kang
Y., 2003).

2.4 Specific to Welding fixtures

The workpiece which is specific to a welding process basically consists of many parts as
compared to workpieces that go through a machining process which contain just one part:

Normally, in a welding process, the level of accuracy required is less than in

machining.
In a welding process, both the machining and fixing forces are less than those in
the machining process.
In welding process, the thermal reactions are a strong consideration. Not just in
the process, these considerations must be considered in the designing of welding
fixtures.
For arc welding stability, the electrical conductivity is critical.
Properties related to thermal expansion need to be considered foremost during
selecting fixture material besides thermal conductivity.
An optimized welding circuit is required to maintain short arc lengths for refined
welding waveforms. This ensures that while spatter is being reduced, arc flare
and arc outages are stubbed to maximize travel speeds.
Dedicated fixtures might be required for certain advanced applications. Their
design and set up would then involve installation and routing of the pneumatic or
hydraulic as well as the wiring (Hui Wanga, 2010).

10
 Figure 2 Automotive related stud weld fixtures on a trunion frame (DBM Innovation, 2016)

2.5 Research in early 2000s

In the welding sector, in the years between 2000 and 2010, only very few CAFD
research has been reported. However, because of the importance of welding in the case
of sheet metal assembly in both the automobile and aerospace sector, it is noticeable that
special attention has been accorded to the assembly and welding of sheet metal. Because
of heat and residual stress in the welding process and to reduce the deformation of each
workpiece, a weld fixture is usually developed with the aim of reducing the dimensional
variation of the assembly. Thus, to enhance the fixtures ability on deformation
controlling, some methods of offline or online deformation analysis were indeed
developed (Sikstrom F, 2008).

11
 Figure 3 Robot weld fixture Source: (Hui Wanga, 2010).

Figure 4 Pin Array Application Source: (Hui Wanga, 2010)

Assembly of sheet metal using laser welding fixtures requires to fit the mating surfaces.
This is important for ensuring quality of the laser weld as well as the correct laser beam
operation. The conventional '3-2-1 locating scheme is further on extended to the total
locating as well as direct locating for the welds. The assembly is then located and so are
the weld joints using the direct locating scheme. These actions confirm to the fit-up
requirements of the metal (Li B, 2003).
 Figure 5 A typical CAFD for Welding Fixtures Source: (Y. Rong, 2016)

2.6 Applications of modular fixtures and dedicated fixtures

There are various classifications of fixtures:

General purpose fixtures

General purpose fixtures can be sub classified as

Modular fixtures
Confirmable fixtures
Reconfigurable fixtures

Both the Confirmable Fixtures Reconfigurable fixtures are configurable in such a

way that they can accept parts that have different sizes and shapes. Of special
significance among the configurable fixtures is the Pin-Array technology (of the
conformable type) is
worth noting (Figure 3). It is used a lot in designing fixtures simply because the various
requirements of the features of the workpieces are easily met by adjusting the variables
in this type of technology. However, in case of precision engineering and manufacturing;
this is particularly true for aerospace engineering, phase-change materials are used
mostly. In the designing and manufacturing of aircraft parts etc., turbine blades are
enclosed by using metals with low melting points. For Clamping and part location
intended for grinding operation, this step produces well defined surfaces (Munro Chris,
2007).

2.7 Welding Fixtures

It is important for properly executed Robotic welding that special fixtures are used to
hold the workpiece stable during the welding operation. If properly designed fixtures are
used, even simple non-versatile 2-axis welding arms would give very good results.
Properly designed fixture would cut costs by reducing the time required to weld as well
as the cost of labor (Prof. S.N.Shinde, 2014).

Welding Fixtures and Positioners

Many types of welding positioners are available:

Headstock positioners

Many having tables that are fixed in a vertical position called headstock positioners.

Tilting positioners

There is another class of positioners available whereby the table tilts over bi-directional
rotating geared segments having a variable speed. All items no matter how small or how
large are welded using these. Welders can weld faster this way and the weld quality also
improves substantially. The rating on these positioners is in terms of CG or center of
gravity which is variable as per the type or design of the positioners. The amount of
torque available with the positioner is indicated by the CG value. The tilting positioners
on the other hand are rated for the level of tilt torque. The rating is both for the face plate
away
but also from the positioners renter table out. These considerations are considered when
offset welding is required for example for tees and elbows (Prof. S.N.Shinde, 2014).

Figure 6 Welding positioner Source: (Prof. S.N.Shinde, 2014).

2.8 Modular Welding Fixtures

As far as the general-purpose fixtures are concerned, the classification that is

used the most world over are the Modular fixtures. Shorter lead times coupled with
proper control over costs are the order of the day due to extreme competition all over the
world in manufacturing. The modular features provide an excellent opportunity to the
manufacturers to remain fully competitive as they constitute flexible manufacturing
systems. Short production batches of different types of parts are more competitive than
mass production of the same type of parts and this awareness is growing with every
passing day all over the manufacturing industry for the past so many years. Modular
fixtures are adaptable; they are versatile and are extreme user friendly and easy to use.
 Figure 7 Modular fixture of a construction machinery part Source: (BLUCO Corporation, 2016)

2.9 Flexibility in manufacturing

A much wider range of flexibility is achieved using modular fixtures. They use
standardized work holding devices along with components. Fixture components have
many different combinations available and these can be configured in many ways. Thus,
there is a lot of flexibility in the modular fixtures. Because of using these flexible
fixtures, the overall cost of the short batches being produced and the lead times required
to deliver these are cut down substantially. The products also assume a great degree of
versatility. Nonetheless, there are limitations attached to modular fixtures as well
(Yufeng, 2006).

The limitations are:

When no suitable combination would be available especially if the workpieces

have a geometry that is either extremely complex and/or irregular.
It is often difficult to maintain modular fixtures' structural geometry. Loading.
Unloading, stiffness, stability, accuracy in loading, speed of operation, etc. are
sometimes very difficult to maintain and control. Thus, a desired quality which
 would be considered optimal might not be able to be achieved using modular
fixtures.
Modular fixtures are more suitable for short batch production. They are not
suitable for mass production in sectors like the automotive sector where mass
production of components and parts is necessary (Yufeng, 2006).

In Figure 7, the construction machinery part used modular fixtures. As a

comparison, the following Figure 8, shows the cases where both mass production
and precision manufacturing of advanced and sophisticated nature is required,
dedicated fixtures can play an important part in such manufacturing processes.
However, as explained earlier, the designing of the dedicated feature is always for a
one particular type of product. This design would have to be customized by the
designer to meet a plethora of various requirements. These would not just include the
stability requirements, stiffness, accuracy of loading but at the same time he would
need to optimally tailor for such requirements as convenience of loading and
unloading, chip disposal, and overall efficiency, etc.

Figure 8 Dedicated fixture for a construction machinery Source: (BLUCO Corporation, 2016) .
2.10 Modern day research concentrates on modular fixtures as well

Dedicated fixtures are very meticulously designed as per the requirements of the
workpiece design as well as other relevant manufacturing requirements. This way, there
are possibilities of many situations where certainty is compromised in the various tasks
to be performed in the design of such fixtures. The modular fixture design has the luxury
of having a library of components, which have already been pre-designed and possess
dimensions that are as per standards. Thus, simply the modular fixture design involves
assembling these predesigned, standardized components into a configuration designed
for the modular fixture. As standardization in production is very popular these days,
most of the research applications being produced these days for Computer Aided Fixture
design consists of modular fixtures to create fixture designs (Zheng Y, 2008).

A McDonnell-Douglas (St. Louis) engineer in 1983 was the first person to come up with
the idea of the computer-aided Fixture Design (CAFD). At that time the idea was
centered on very simple functions like database of fixture component and customizing of
CAD interface manual. The objective was simply to save both time and effort to
implement and execute fixture design in a more managed manner. However, now CAFD
has advanced to a very high level of technology (Y. Rong, 2016).

When CAFD had initially been developed, and utilized, the simple drafting function of
CAD software packages were utilized. Clamps, supports, baseplates, locators etc. which
are all modular fixture elements stored in the database. Starting the design process, the
surface points of the primary locator had to be specified along with the positions of the
locator. Similarly, surfaces and positions for clamps were inputted. Once done, the
components were required to be placed in the positions desired. Designer experience is
the key in this approach as this is basically a manual design process supported by CAD
tools which were basically functional extensions in the simple CAD package. Thus,
there are still limitations in this approach. Attempts have been continuing throughout to
incorporate more fixture design knowledge into CAD packages to be able to execute
semi or fully automated CAFD. (Hui Wanga, 2010).
Many manufacturers today provide custom built welding fixtures for the manufacturers
these days. They develop a comprehensive library of manufactured welding fixtures for
3D / Solidworks or other formats. Thus, manufacturing has become very collaborative
and distributed these days.

2.11 Case Based Reasoning (CBR)

Case based reasoning (CBR) is about using precedence of a problem and its solution that
was found as the basis for explanation ad solution of current problems. This is reasoning
that is based on analogy or a precedence. Thus, a guidance from history to find a
solution for the present. CBR has 2 approaches:

Interpretive
Problem solving

Interpretive

Current problems are connected to previous solutions and tries to prove that same
solution would be valid.

Problem solving

Based on past occurrences and solutions that were found, similarities are found with
present problems and a new solution is found based on learning from the previous
solutions.

CAFD and CBR are applied together to find new solutions for welding assemblies and
fixtures based on experience. Thus, fixtures can be developed based on historical data
that have the required versatility to adapt to the new situation but are confirmed as tested
and tried in a previous similar situation. Thus, previous mistakes are avoided and
successes
reconfirmed. There is no need for proof that fixture would work as it has already proven
itself in the past.

2.12 Rule based Fixturing system

The rule based technique is perfectly suitable for this kind of an expert system since it is
constructed to simulate the design made by expert tool designers. The rule based
framework is a critical perspective of knowledge designing, the portion of artificial
intelligence particular for constructing frame works of this kind.

There are three main components for the rule based system.

1. Database
2. Rules
3. Control strategy

2.12.1 Database: A proper database is mandatory to setup any rule based system. In this
case, the database comprises of following.

Sold models of adaptable fixture elements

Solid models of workpieces to be fixtured
Rules for creating fixturing sites and locating clamping locations
Knowledge frames

The database will further convey an information of present task area circumstance and
the planned objective.

2.12.2 Rules

There are a set of directions utilized to control the database. In this case, the rules
created will list all the vital information connected with fixturing for welding operations.
These incorporate fixturing positions, clamping locations, workpiece size and shapes. A
definite investigation of the rules and their capacities are explained in the following
section.

20
2.12.3 Control Strategy

This part of the expert system manages the decision making. An adequate control
technique is one that can accomplish the desired objective by applying an arrangement
of fixturing rules. The control technique should be competent of modifying
circumstances by utilizing these rules and deciding their impact on the task.

The expert system is developed on the above grounds and will have the capacity to
consequently and logically assemble the fixture components around the workpiece on
the CAD software for welding operations. Solid models of workpieces that are saved in
the CAD database might be seen as individual from a group of basic elements.
Accordingly, the following step is to create methodologies for fixturing each group of
basic elements. At this point, a sensible place to start fixturing would be with flat shaped
elements such as polygonal prisms. The operation involved is welding operation and a
general technique to depict is shown below. (Nnaji)

2.13 Automation of the Clamping design process

The most basic of manufacturing process is clamping. During welding at very high
temperatures, many forces can cause deformations and thus clamping is critical to
welding operations. For welding professionals, it is a necessary requirement to specify
clam positions. This often require a lot of valuable time and experience. A particularly
complex with 4 or 5 workpiece assembly design might require many days to be
calculated correctly although simpler tasks can be accomplished in a few hours
manually. It is imperative for the engineer to find safe positions for workpieces so they
could be welded and joined together. He thus, must calculate forces and specify
clamping positions. Many man hours of engineers are consumed in these trial and error
operations especially for small or medium sized companies (Intelligent welding clamp
design software using computer- aided optimization, 2014).

Decision support systems such as CLAMPIT and others are available these days to
automate the calculation process. Thus, the clamping design process gets automatized.

21
Such programs also use CBR (Case Base Reasoning) historical data to automate the
process. Each new case is saved again and is available in the knowledge database to be
used for similar but newer issues. Thus, the system keeps expanding in capabilities and
outreach (Intelligent welding clamp design software using computer-aided optimization,
2014).

2.14 Fixture Design Analysis

The quality of the fixture design is evaluated by analysis. Many functions indicating the
quality have been developed. These are:

Fixturing constraint analysis

Fixture constraints are identified and so is under locating and over locating. This also
gives an indication of the direction of the problem.

Fixturing accuracy analysis

Evaluation of tolerance stack-up effect a true position or parallelism is possible.

Sensitivity analysis can also be performed. Economic criteria need to be considered to
arrive at a final tolerance solution as there would be no absolute solution.

Clamping stability analysis

Upon application of clamping force, the clamping contact might be damaged. As friction
force is involved, calculations are very complex.

Dynamic stability analysis

Evaluation of locating forces are derived from the cutting force and tool path data over
time. The fixture's dynamic stiffness is still hard to estimate.

Fixturing surface accessibility analysis

Locating or clamping surface once selected needs to be checked for clamp placement on
it. CAD based methods are used to identify placement area.

Loading and unloading accessibility analysis

The ease of loading and unloading is determined by CAD based methods and in case of
fixture design change, the time required to do these.

Fixturing stiffness

Against boundary conditions imposed by fixture design, workpiece deformation is

determined due to machining and clamping.

Fixture structural stiffness

Nonlinear stiffness occurs due to contact between the fixture and workpiece. FEA
(Finite Element Analysis) is used to determine this stiffness. If fixture is designed via
CAFD, verification can be done before launch of the product (Y. Rong, 2016).

3.0 Proposed Approach

The project objective is to build a methodology to design and automate the assembly of
modular welding fixture design. This project is divided into various tasks to complete
the objectives stated.

The first step is to create a design library in Solidworks, which holds the components of
the fixturing system. All the solid files of the fixture are stored in different sections
according to their function.

The second step is to develop a set of rules which will help in locating the fixture
components. These rules are developed based on the information of the client.

In the next semester the remaining objectives will be achieved.

Flow charts will be constructed. In the flow charts, the inputs are derived from the
dimensions of the workpiece and also the type of welding operation performed will be
included.

After the flowcharts are constructed, these flow charts are used to automate the fixture
design assembly with the help of Driveworks Express which is an extension of
Solidworks. Rules are created in Driveworks express which will drive the solid models.
There are different types of rules like configurations, custom properties and dimensions.
By selecting the dimension rules, length width and depth are entered. Using the logic
menu, If and Then statements are selected to finish the rule.

4.1 preliminary result and discussion

4.2 Creation of design library

The modular fixtures has many components, a database should be created for the parts
designed. The feature in the solid works named design library is used to save the
designed parts of the modular welding fixture. This library is exceptionally helpful to
choose the required parts and it can be reusable. A folder was created in design library as
Modular welding fixtures which has a subfolders of welding tables, locators, clamps and
work piece. The figure illustrates the design library for the modular welding fixtures.
Figure 9 Design library

The design Library consists of the parts which are included in the table below.
Welding Tables Clamps Locators & Supports Work Pieces
1960mm1000mm Round stock pliers V block Work piece prismatic

2960mm1000mm Table mount clamp 1 Straight edge stops Work piece circular

2600mm1250mm Table mount clamp 2 Right angle brackets

1150mm1160mm Mag spring clamps Support cylinders

Table 1 List of Components in Design Library

 Figure 10 Fixture assembly in Solidworks

4.3 Rules for the selection of modular welding fixture components

4.3.1 Welding table selection
Rule 1. If the work piece total dimensions range from (1-100mm) (1-400mm)
then select a grid plate of dimensions 1150mm 1160mm.
Figure 11 Welding Table 1150mm 1160mm
 Start

Work
Piece 1

Analyse and Determine welding feature of work piece

Is it Welding
No
Operaton?

Yes

Use welding table

Are the Select Suitable size

Dimensions L < 100
No
B < 400

Yes
Use welding table 11501160 Dsign Library

End

Flow chart 1 Welding table selection

Rule 2. If the work piece total area range from (1-400mm) (1-1000mm) then
select a grid plate of dimensions 1960mm 1000mm.
 Figure 12 Welding Table 1960mm 1000mm

Rule 3. If the work piece total area range from (1-1000mm) (1-2000mm) then
select a grid plate of dimensions 2960mm 1000mm.

Figure 13 Welding Table 2960mm 1000mm

 Rule 4. If the work piece total area range from (1-2500mm) (1-8000) then
select 3 grid plates of dimensions 2600mm 1250mm.

Figure 14 Welding Table 2600mm 1250mm

4.3.2 Locating principles for selection of components

Rule 5. If the work pieces are circular with a radii of 1-50mm the select a V-
Block 1.

30
 Start

Work
piece

Is the work piece Use supports

circular? No

Yes

Use V-block

Radii <50mm? Select

Length < 500mm? No suitable

size

Yes

Use V- Design
block 1 Library

End

Flow chart 2 Selection of supports

31
 Rule 6. If there are work pieces is semicircular and top surface is flat then select
a mini V block.

Rule 7. If the two work pieces are prismatic and motion should be fixed in X
direction then select support cylinders.

Rule 8. If the two work piece are prismatic and motion should be fixed in Y
direction then select Right angle brackets.

4.3.3 Clamping rules for the selection of components

Rule 9. If the welding operation is performed on prismatic work pieces then

select table mount C clamps.

start

Work
Piece

Use 3 round stock pliers

Is the work
No
piece prismatic

Yes
Use 3 Table mount C-clamps Design Library

End

Flow chart 3 Selection of clamps

 Rule 10. If the welding operation is performed on circular work pieces then
select round stock pliers.

Rule 11. If the welding operation is performed to join a prismatic work piece and
circular work piece then select table mount clamps and round stock pliers.

Rule 12. If the work piece is semicircular and rectangular surface is to be welded
then top clamping should be used.

Rule 13. If the work piece is semicircular and circular part is to be welded then
select toggle clamps.
5 Conclusion & Future Work

5.1 Conclusion

Literature study on various modular welding fixtures is carried out. Design library was
created in Solidworks. Various fixture components are stored in the design library. If
then rules are created to help the automation of fixture selection process.

5.2 Future work

Flow charts will be constructed relying on the inputs that have been created using rules.
These flow charts will assist in selection of fixture components.

To automate the fixture design assembly the constructed flow charts will be used in
Driveworks Express tool which is an extension of Solidworks.
References
(2016). Retrieved from BLUCO corporation: http://www.bluco.com/

Boyle I., R. Y. (2011). A review and analysis of current computer-aided fixture design
approaches,. Robotics and Computer-Integrated Manufacturing.

Boyle, I. (2006). CAFixDa case-based reasoning method for fixture design. Worcester
Polytechnic Institute.

DBM Innovation. (2016). Retrieved from DBM Innovation.

Farhan, U., & Tolouei-Rad, M. (2011). Design of modular fixtures using a 3D-modelling.

Farhan, U., O'Brien, S., & Rad, M. T. (2012). SolidWorks Secondary Development with Visual
Basic 6 for an Automated Modular Fixture.

Heidar Hashemi, A. M. (2016). Recent Developments on Computer Aided Fixture Design: Case
Based Reasoning Approaches. Sage Publications.

Huang, R. &. (2005). Advanced Computer-Aided Fixture Design, 1st Edition. Academic Press.

Hui Wanga, Y. (. (2010). Computer aided fixture design: Recent research and trends. Elsevier.

Intelligent welding clamp design software using computer-aided optimization. (2014).

PHYS.org.

Joneja, A., & Chang, T.-C. (n.d.). Setup and Fixture Planning in Automated Process Planning
Systems.

Kang Y., R. Y. (2003). Computer-aided fixture design verificationpart 1. The framework and
modelling,. The International Journal of Advanced Manufacturing Technology.

Kang, Y. (2001). COMPUTER-AIDED FIXTURE DESIGN VERIFICATION. WORCESTER POLYTECHNIC

INSTITUTE.

Li B, S. B. (2003). Robust fixture configuration design for sheet metal assembly with laser
welding. Journal of Manufacturing Science and Engineering.

Munro Chris, W. D. (2007). Reconfigurable pin-type tooling: a survey of prior art and reduction
to practice. Journal of Manufacturing Science and.

Nelaturi S., R. A. (2014). Automated fixture configuration for rapid manufacturing planning.
Computer-Aided Design.

Nnaji, B. O. (n.d.). A Framework for a Rule-based Expert Fixturing System for Face Milling Planar
Surfaces on a CAD.

Prof. S.N.Shinde, S. K. (2014). Design of Welding Fixtures and Positiners. International Journal of
Engineering Research and General Science Volume.

S., P. (2009). A study of case based reasoning applied to welding computer aided fixture design.
Worcester Polytechnic Institute.
Sikstrom F, E. M.-K. (2008). Tools for simulation based fixture design to reduce deformation in
advanced fusion welding. In: The 1st International conference on intelligent robotics
and applications. Part II. .

U.H., F. (2013). An integrated computer-aided modular fixture design system for semi circular
parts. 4-18.

Y. Rong, J. W. (2016). Computer-Aided Fixture Design: An Update. Advanced Manufacturing.

Yufeng, W. (2006). Geometry generation for computer-aided fixture design *Master thesis).
Southern Illinois University at Carbondale.

Zheng Y, Q. W.-H. (2008). A 3-D modular fixture with enhanced localization accuracy. Journal of
Machine Tools and.
6. O Appendices

6.1 Welding Table specifications

6.1.1 Welding Table with 1150mm1160mm

6.1.2 Welding Table with 196mm01000mm
6.1.3 Welding Table with 2960mm1000mm
6.2 Clamps
6.2.1 Mag spring Clamp

40
6.2.2 Table mount C-clamp

41
6.2.3 Round Stock Pliers
6.3 Locators
6.3.1 V-block
6.3.2 Support
6.4 Fixture Assembly