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Numerical simulation of the system “fixture–workpiece” for lever machining

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Abstract

In this article, the new configuration of fixture was proposed for ensuring the sufficient tool accessibility, which allows carrying out multiaxis machining of levers in one setup. The research based on numerical simulation was confirmed that the proposed fixture corresponds to all the accuracy parameters. Workpieces from steel, cast iron and aluminium alloy were investigated within the simulation. The values of displacements and stresses occurring during machining are less for proposed fixture in comparison with the existing fixtures that was confirmed by the deflected mode analysis. The modal analysis proved that the proposed fixture has much higher value of eigenfrequency than the other fixtures. To optimize the machining, the dependences for displacements and stresses on the cutting depth were determined. Oscillations of the system “fixture–workpiece” during machining were investigated for various manufacturing steps of levers machining of the fixtures from different fixture systems. The results of harmonic analysis showed that the dynamic stiffness of the proposed fixture was higher than that for the dedicated and modular fixtures. The oscillation amplitudes in the places of machined surfaces in the proposed fixture do not exceed the tolerance requirements for lever manufacturing.

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Authors and Affiliations

  1. Faculty of Technical Systems and Energy Efficient Technologies, Department of Manufacturing Engineering, Machines and Tools, Sumy State University, Sumy, Ukraine

    Vitalii Ivanov & Ivan Dehtiarov

  2. Faculty of Manufacturing Technologies with a seat in Presov, Department of Manufacturing Technologies, Technical University of Kosice, Presov, Slovakia

    Dusan Mital, Jozef Zajac & Michal Hatala

  3. Faculty of Engineering, Department of Mechanical Engineering, National Academy of National Guard of Ukraine, Kharkiv, Ukraine

    Vladyslav Karpus

  4. Faculty of Technical Systems and Energy Efficient Technologies, Department of General Mechanics and Machine Dynamics, Sumy State University, Sumy, Ukraine

    Ivan Pavlenko

Authors
  1. Vitalii Ivanov
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  2. Dusan Mital
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  3. Vladyslav Karpus
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  4. Ivan Dehtiarov
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  5. Jozef Zajac
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  6. Ivan Pavlenko
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  7. Michal Hatala
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Correspondence to Dusan Mital.

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Ivanov, V., Mital, D., Karpus, V. et al. Numerical simulation of the system “fixture–workpiece” for lever machining. Int J Adv Manuf Technol 91, 79–90 (2017). https://doi.org/10.1007/s00170-016-9701-2

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  • DOI: https://doi.org/10.1007/s00170-016-9701-2

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