A parametric FEA system for fixturing of thin-walled cylindrical components

Abstract Machining of thin-walled components has increasingly become a difficulty for manufacturers. Advanced digital analyses have been developed by many researchers to model, predict and reduce errors induced by machining processes. Fixtures for thin-walled components to increase the rigidity of components, improve dynamic performance and reduce machining cost have been widely used in industries. However, modelling to simulate the impact of fixture on the quality of thin-walled components is seldom reported. Moreover, today's machining shop floors, characterized by a large variety of products in small batch sizes, require flexible simulation tools that can be quickly reconfigured. Parametric technology is a key to implement it. This paper proposed a parametric finite element analysis (FEA) system that can automatically mesh components, assign material properties and boundary condition, and create FEA files ready for calculation with limited human interference. The system is focused on thin-walled cylindrical components, including straight thin-walled cylinder, conic thin-walled cylinder and angle-varying thin-walled cylinder. Based on the FE prediction, whether or not a fixture is required and the impact of a support fixture on the component quality can be assessed.