Skip to main content

Advertisement

SpringerLink
Log in

Locator Placement Optimization for Minimum Part Positioning Error During Machining Operation Using Genetic Algorithm

  • Regular Paper
  • Published:
International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

A Correction to this article was published on 16 April 2021

This article has been updated

Abstract

Fixture design is one of the main factors which affect the final product quality. Proper design of fixture plays an important role in ensuring the required tolerance of the product. Proper placement of locators is one of the prominent factors in fixture design. Locators are elastic: they deform under clamping and machining forces causing rigid body displacement of the workpiece which in turn affects the part quality. In this article, a 3-2-1 type of fixturing system having elastic locators around a considerably rigid rectangular workpiece is considered. A genetic algorithm is proposed, which uses a fitness function that evaluates the positioning error of the workpiece under external forces and torque. Among several variables, 12 variables, which define the placement of locators, are chosen to be optimized while minimizing the positioning error of the workpiece at the point of action of machining force. The proposed algorithm optimizes the 12 interlinked variables, within the specified region, for machining force and torque at a single point. However, when the cutting tool moves to any other point on the workpiece, it is observed that either the workpiece loses its contact with any one of the locators or the positioning error increases by a large value. To overcome this issue, the proposed algorithm is further modified for placement optimization to cater for multi-point machining, and the isostatism of the workpiece is ensured by checking the magnitude and direction of displacement (of what?) at each point of workpiece-locator contact. Finally, the original and modified GA algorithms are explained through a case study where the single point optimized placement shows loss of contact when machining force is applied at other points. The placement optimized from the modified algorithm shows that the isostatism of the workpiece remains intact while all four positioning errors are converged towards the same value. The results obtained from the proposed and modified algorithm are verified using ANSYS simulation.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22

Similar content being viewed by others

Change history

References

  1. Vasundara, M., & Padmanaban, K. P. (2014). Recent developments on machining fixture layout design, analysis, and optimization using finite element method and evolutionary techniques. International Journal of Advanced Manufacturing Technology, 70(1–4), 79–96. https://doi.org/10.1007/s00170-013-5249-6

    Article  Google Scholar 

  2. Butt, S. U., Antoine, J. F., & Martin, P. (2012). An analytical model for repositioning of 6 D.O.F fixturing system. Mechanics & Industry, 13(03), 205–217. https://doi.org/10.1051/meca/2012016

    Article  Google Scholar 

  3. Nasr, E. A., Al-Ahmari, A., Kamrani, A., Khan, A. A. (2011). An integrated system for automatic computer aided fixture design. In: the 41st International Conference on Computers & Industrial Engineering, p. 654.

  4. Li, B., & Melkote, S. N. (1999). Improved workpiece location accuracy through fixture layout optimization. International Journal of Machine Tools and Manufacture, 39(6), 871–883.

    Article  Google Scholar 

  5. Somashekar, S. R. (2002). Fixturing features selection in feature-based systems. Compters in Industry, 48(2), 99–108. https://doi.org/10.1016/S0166-3615(02)00037-4

    Article  Google Scholar 

  6. Roy, U., & Liao, J. (2002). Fixturing analysis for stability consideration in an automated fixture design system. Journal of Manufacturing Science and Engineering, 124(1), 98–104. https://doi.org/10.1115/1.1413778

    Article  Google Scholar 

  7. Wang, M. Y. (2002). Research article tolerance analysis for fixture layout design. Assembly Automation, 22(2), 153–162.

    Article  Google Scholar 

  8. Wang, H., Huang, L., Yao, C., Kou, M., Wang, W., Huang, B., et al. (2015). Integrated analysis method of thin-walled turbine blade precise machining. International Journal of Precision Engineering and Manufacturing, 16(5), 1011–1019.

    Article  Google Scholar 

  9. Bourdet, P. (1999). Logiciels des machines à mesurer tridimensionnelles. Techniques de l’ingénieur. Mesures et contrôle, R1316, R1316–R1321.

    Google Scholar 

  10. Clement, A., & Bourdet, P. (1988). A study of optimal-criteria identification based on the small-displacement screw model. CIRP Annals-Manufacturing Technology, 37(1), 503–506.

    Article  Google Scholar 

  11. Villeneuve, F., Legoff, O., & Landon, Y. (2001). Tolerancing for manufacturing: A three-dimensional model. International Journal of Production Research, 39(8), 1625–1648.

    Article  Google Scholar 

  12. Asante, J. N. (2009). A small displacement torsor model for tolerance analysis in a workpiece-fixture assembly. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 223(8), 1005–1020.

  13. Jayaram, S., El-Khasawneh, B. S., Beutel, D. E., & Merchant, M. E. (2000). A fast analytical method to compute optimum stiffness of fixturing locators. CIRP Annals-Manufacturing Technology, 49(1), 317–320.

    Article  Google Scholar 

  14. Raghu, A., & Melkote, S. N. (2005). Modeling of workpiece location error due to fixture geometric error and fixture-workpiece compliance. Journal of Manufacturing Science and Engineering, 127, 75.

    Article  Google Scholar 

  15. Hurtado, J. F., & Melkote, S. N. (2001). Improved algorithm for tolerance-based stiffness optimization of machining fixtures. Journal of Manufacturing Science and Engineering, 123(4), 720–730. https://doi.org/10.1115/1.1403446

    Article  Google Scholar 

  16. Asante, J. N. (2010). Effect of fixture compliance and cutting conditions on workpiece stability. International Journal of Advanced Manufacturing Technology, 48(1), 33–43.

    Article  Google Scholar 

  17. Marin, R. A., & Ferreira, P. M. (2003). Analysis of the influence of fixture locator errors on the compliance of work part features to geometric tolerance specifications. Journal of Manufacturing Science and Engineering, 125(3), 609–616. https://doi.org/10.1115/1.1578669

    Article  Google Scholar 

  18. Liao, Y. G., & Hu, S. J. (2001). An integrated model of a fixture-workpiece system for surface quality prediction. International Journal of Advanced Manufacturing Technology, 17, 810–818. https://doi.org/10.1007/s001700170108

    Article  Google Scholar 

  19. Hsu, Y. Y., & Wang, S. S. (2007). A new compensation method for geometry errors of five-axis machine tools. International Journal of Machine Tools and Manufacture, 47(2), 352–360. https://doi.org/10.1016/j.ijmachtools.2006.03.008

    Article  Google Scholar 

  20. Lin, Y., Shen Y.-L. (2000). A Generic Kinematic Error Model for Machine Tools. Citeseer.

  21. Ahn, K. G., & Cho, D. W. (2000). An analysis of the volumetric error uncertainty of a three-axis machine tool by beta distribution. International Journal of Machine Tools and Manufacture, 40(15), 2235–2248.

    Article  Google Scholar 

  22. Choi, J. P., Min, B. K., & Lee, S. J. (2004). Reduction of machining errors of a three-axis machine tool by on-machine measurement and error compensation system. Journal of Materials Processing Technology, 155, 2056–2064.

    Article  Google Scholar 

  23. Jha, B. K., & Kumar, A. (2003). Analysis of geometric errors associated with five-axis machining centre in improving the quality of cam profile. International Journal of Machine Tools and Manufacture, 43(6), 629–636. https://doi.org/10.1016/S0890-6955(02)00268-7

    Article  Google Scholar 

  24. Zhu, S., Ding, G., Qin, S., Lei, J., Zhuang, L., & Yan, K. (2012). Integrated geometric error modeling, identification and compensation of CNC machine tools. International Journal of Machine Tools and Manufacture, 52(1), 24–29. https://doi.org/10.1016/j.ijmachtools.2011.08.011

    Article  Google Scholar 

  25. Martin, P., Dantan, J. Y., & D’Acunto, A. (2011). Virtual manufacturing: prediction of work piece geometric quality by considering machine and set-up accuracy. International Journal of Computer Integrated Manufacturing, 24(7), 610–626.

    Article  Google Scholar 

  26. Wan, X.-J., Xiong, C.-H., Zhao, C., & Wang, X.-F. (2008). A unified framework of error evaluation and adjustment in machining. International Journal of Machine Tools and Manufacture, 48(11), 1198–1210. https://doi.org/10.1016/j.ijmachtools.2008.03.014

    Article  Google Scholar 

  27. Zhang, S., He, C., Liu, X., Jinghua, X., & Sun, Y. (2020). Kinematic chain optimization design based on deformation sensitivity analysis of a five-axis machine tool. International Journal of Precision Engineering and Manufacturing, 21(12), 2375–2389.

    Article  Google Scholar 

  28. Wang, K., Shichang, D., & Xi, L. (2020). Three-dimensional tolerance analysis modelling of variation propagation in multi-stage machining processes for general shape workpieces. International Journal of Precision Engineering and Manufacturing, 21(1), 31–44.

    Article  Google Scholar 

  29. Wang, Jin-Dong, Wang, Qing-Jie, & Li, Hai-Tao. (2019). The method of geometric error measurement of NC machine tool based on the principle of space vector’s direction measurement. International Journal of Precision Engineering and Manufacturing, 20(4), 511–524.

    Article  Google Scholar 

  30. Necmettin, K. (2006). Machining fixture locating and clamping position optimization using genetic algorithms. Computers in Industry, 57(2), 112–120. https://doi.org/10.1016/j.compind.2005.05.001

    Article  Google Scholar 

  31. Padmanaban, K. P., Arulshri, K. P., & Prabhakaran, G. (2009). Machining fixture layout design using ant colony algorithm based continuous optimization method. International Journal of Advanced Manufacturing Technology, 45(9–10), 922–934. https://doi.org/10.1007/s00170-009-2035-6

    Article  Google Scholar 

  32. Xie, W., Deng, Z., Ding, B., & Kuang, H. (2015). Fixture layout optimization in multi-station assembly processes using augmented ant colony algorithm. Journal of Manufacturing Systems, 37, 277–289. https://doi.org/10.1016/j.jmsy.2014.08.005

    Article  Google Scholar 

  33. Dou J., Wang, X., Wang, L. (2011). Machining fixture layout optimization using particle swarm optimization algorithm. In: Fourth international seminar on modern cutting and measurement engineering, 7997, p. 79970S.

  34. Krishnakumar, K., & Melkote, S. N. (2000). Machining fixture layout optimization using the genetic algorithm. International Journal of Machine Tools and Manufacture, 40(4), 579–598. https://doi.org/10.1016/S0890-6955(99)00072-3

    Article  Google Scholar 

  35. Subramaniam, V., Kumar, A. S., & Seow, K. C. (1999). Conceptual design of fixtures using genetic algorithms. International Journal of Advanced Manufacturing Technology, 15(2), 79–84. https://doi.org/10.1007/s001700050042

    Article  Google Scholar 

  36. Vallapuzha, S., De Meter, E. C., Choudhuri, S., & Khetan, R. P. (2002). An investigation into the use of spatial coordinates for the genetic algorithm based solution of the fixture layout optimization problem. International Journal of Machine Tools and Manufacture, 42(2), 265–275. https://doi.org/10.1016/S0890-6955(01)00113-4

    Article  Google Scholar 

  37. Wu, N. H., & Chan, K. C. (1996). A genetic algorithm based approach to optimal fixture configuration. Computers & Industrial Engineering, 31(3–4), 919–924. https://doi.org/10.1016/S0360-8352(96)00264-1

    Article  Google Scholar 

  38. Abedini, V., Shakeri, M., Siahmargouei, M. H., Baseri, H. (2014). Analysis of the influence of machining fixture layout on the workpiece’s dimensional accuracy using genetic algorithm. In: Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 228(11), 1409–1418.

  39. Wan, X.-J., Xiong, C.-H., Wang, X.-F., Zhang, X.-M., & Xiong, Y.-L. (2010). A machining-feature-driven approach to locating scheme in multi-axis milling. International Journal of Machine Tools and Manufacture, 50(1), 42–50. https://doi.org/10.1016/j.ijmachtools.2009.09.008

    Article  Google Scholar 

  40. Butt, S. U., Antoine, J.-F., & Martin, P. (2013). A kinematic approach for 6-DOF part positioning. In M. Abramovici & R. Stark (Eds.), Smart product engineering (pp. 147–157). Springer.

    Chapter  Google Scholar 

  41. Butt, S. U. (2012). Design and modelling of a fixturing system for an optimal balancing of a part family. phdthesis, Arts et Métiers ParisTech.

  42. Kyratsis, P., Markopoulos, A. P., Efkolidis, N., Maliagkas, V., & Kakoulis, K. (2018). Prediction of thrust force and cutting torque in drilling based on the response surface methodology. Machines, 6(2), 24. https://doi.org/10.3390/machines6020024

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering (CEME), National University of Sciences and Technology (NUST), Sector H-12, Islamabad, 4600, Pakistan

    Sajid Ullah Butt, Mamoona Arshad, Aamer Ahmed Baqai, Hasan Aftab Saeed, Naveed Akmal Din & Rehan Ahmed Khan

Authors
  1. Sajid Ullah Butt
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mamoona Arshad
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Aamer Ahmed Baqai
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Hasan Aftab Saeed
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Naveed Akmal Din
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Rehan Ahmed Khan
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Sajid Ullah Butt.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Butt, S.U., Arshad, M., Baqai, A.A. et al. Locator Placement Optimization for Minimum Part Positioning Error During Machining Operation Using Genetic Algorithm. Int. J. Precis. Eng. Manuf. 22, 813–829 (2021). https://doi.org/10.1007/s12541-021-00500-6

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12541-021-00500-6

Keywords

Search

Navigation