Proceedings of the 7th Cairo University International Conference on Mechanical Design &

Production, MDP-7, Cairo–Egypt, February 15- 17, 2000, pp. 251-260

Framework for Computer Aided Fixture Design and Manufacture System

Gadalla, M. A. E*., Kridli, G.T.**, Orady, E. A.**, Yoon, D.**

*Cairo University, Faculty of Engineering, Cairo, Giza 12316, Egypt.

**University of Michigan-Dearborn, Dearborn, MI 48128-USA.
e-mails: orady@[Link] & gadalla@[Link]

ABSTRACT

Currently fixtures can be divided into two main categories: flexible (modular) and
dedicated fixtures. In the former, the structure of the fixture is built based on a set of modular
components that are selected from off-the-shelf components. This type of fixture is
commonly used on milling machines, CNC machines, and coordinate measuring machines
(CMM). In the latter category, a fixture structure is built using dedicated specially designed
components. This type is mostly built to meet certain functional criteria such as the ease of
loading and unloading of workpieces, adjustable and programmable fixtures that are suitable
for robotic assembly, and/or complex shaped parts.
The objective of this work is to provide a design framework for a computer-aided
system design and manufacture of machining fixtures. The main characteristics of the system
is to provide the capability to identify locating and fixing surfaces on the workpiece to
determine the safe and proper holding forces, the capability to relate holding forces to the
machining forces to determine the effect of the holding forces on the critical dimensions of
the workpiece, and the ability of extending to other manufacturing fixtures.

KEYWORDS

Computer-Aided Fixture Design (CAFD), CAPP, Flexible Fixture, Dedicated Fixtures

1.0 INTRODUCTION

A fixture is a work holding device used in manufacturing and assembly operations to

serve in locating, clamping, and supporting the workpiece. Currently, fixture design is based
on the knowledge and experience of the tool design and manufacturing engineers.
Verification of the workability of the fixture is often carried out by trial and error. Fixture
design is a three-step activity: (1) setup planning, (2) fixture planning, and (2) determination
of fixture configuration [1]. The setup planning process is designed to determine the number
of the setups needed and workpiece orientation in each setup. It can be considered as a subset
of the process planning activity hence it can be searched in computer-aided process planning
(CAPP) work. Fixture planning was the focus of many research studies in the area of
computer-aided fixture design (CAFD) [1, 2]. It mostly focuses on determining the locating
and the clamping points. Automatic generation of fixture configuration would reduce the
design efforts and secure consistency of products.
Proceedings of the 7th Cairo University International Conference on Mechanical Design &
Production, MDP-7, Cairo–Egypt, February 15- 17, 2000, pp. 251-260

To understand the importance of fixturing, product development cycle can be divided

into three phases: a) product design, b) product preparation (process planning and tooling),
and c) product manufacture [1]. In an advanced manufacturing environment, these stages can
be described as computer-aided design (CAD), computer-aided process planning and tooling
(CAPP/ CAT) and computer-aided manufacturing (CAM).
Advances in systems such as I-DEAS, CATIA, UG and Pro/Engineer made them
suitable not only for the drafting and design of products, but also for carrying out stress,
thermal, and dynamic analyses. These systems can also be used to conduct parametric design
where the part can be scaled out in dimensions to fit the design requirements for a specified
function. This makes it easy to design a small library of parts that can be modified when
needed to design a new product such as a fixture.
Product preparation (CAPP/ CAT) deals with the preparation of the sequence of the
manufacturing processes as well as their technological parameters such as the cutting speed,
feed rate, depth of cut etc. Estimation of the manufacturing time is well desired in this phase
to provide other links to other planning and control activities. This phase was the subject of
research for the past three decades and is available in many commercia l systems such as
METCUT and EXAPT I, II. The choice of tooling is affected, in most cases, by the type of
fixture used. It is also well known that part loading and unloading are nonproductive steps
that need to be minimized. The design of a proper fixture would lead to substantial reduction
of part handling time in the manufacturing stages.
This paper presents a framework for the design of fixture based on the integration of
some of the above mentioned systems. Procedures for development of a comprehensive
system for fixture design are presented and discussed. The following sections are devoted for
a presentation of fixture types, review of existing computer aided systems.

2.0 FIXTURE CLASSIFICATION

Fixtures can be classified according to the manufacturing processes that utilizes them;
such as machining, welding, and assembly fixtures. Machining fixtures can be divided into
two main classes; a) flexible, and b) special design (dedicated). Flexible fixtures can be
further categorized into: flexible fixtures with phase-change materials, programmable
(reconfigurable) fixtures, adjustable fixtures, and modular fixtures.
The most commonly used of the flexible fixtures is the modular fixtures category. The
modular fixtures are designed so that the action of fixing the part is achieved by using a set of
standard off-the-shelf fixturing components (baseplates, clamps and locators) that provide a
basic structure and the holding actions. This type of fixture is common for holding parts on
milling machines, planers, and coordinate measuring machines (CMM). This approach
provides a wide variety of workholding configurations.
In the phase change fixtures, the fixturing action is achieved by phase change of the
workholding material; in this case a fluid changes to solid after the workpiece is immersed in
it, and after processing the part, it changes back to liquid [2]. Programmable fixtures are
mainly used in assembly. The basic design simplification for assembly fixtures, as opposed
to machining fixtures, is the lack of consideration for high cutting forces. Reconfigurable
fixtures have to be modular (i.e. flexible), automatically reconfigurable (e.g. by a robot),
capable of providing sensory feed back, and programmable by a computer [3]. Benhabib et.
al. [3] developed a modular programmable fixture system (MPFS) that includes specially
designed horizontal locators, vertical locators, V-blocks with universal clamp, and T-slot type
baseplates along with transducers. Sensors are used to provide information such as,
verification of the proper insertion of the fixture components into the baseplate, detection of
Proceedings of the 7th Cairo University International Conference on Mechanical Design &
Production, MDP-7, Cairo–Egypt, February 15- 17, 2000, pp. 251-260

the workpiece presence, and control of the clamping process. The control actions are
achieved through a computer equipped with interface cards.
Adjustable fixtures are designed for part families using group technology (GT) to
identify similar part families with fixturing information [4]. The idea is that parts in the same
family have similarity in the structure, shape, and other features, hence they require the same
basic fixturing structure and mechanism. Therefore, the fixturing action is achieved by
adjusting some fixture elements according to part dimensions.
Dedicated fixtures are designed when it is required to hold tight tolerances that can
not be achieved using flexible fixtures or automated fixturing action in low production rate
environment. The design of such fixtures requires careful consideration of the strength of the
components constituting the fixture, ease of operation, ease of assembly and disassembly, and
ease of loading and unloading [5].

3.0 COMPUTER AIDED FIXTURE DESIGN SYSTEMS (CAFD)

Computer aided fixture design systems can be classified into the following systems:
A. Interactive Computer Aided Fixture Design (I-CAGFD)
Owing to the complexity of fixture design, human involvement in decision making
helps in improving the speed and efficiency of the fixture design process [6]. In I-CAFD
systems, the system provides designer assist tools, in addition to normal CAD functions, for
convenie nce and for fast operations of the design of fixture configuration. FIX-DES
developed by Ma et. al. is an example of such a system that is capable of both interactive and
automated fixture designs. In FIX-DES, the system is designed so that the CAD package acts
as a development platform using standard commands. Application Program Interface (API)
is developed to interface between the CAD system and the core programs, which are
developed in C and C++. This structure also makes the system easily integrable; however, it
does not have links to accuracy analysis modules .
B. Group Technology (GT) Based Fixture Design Retrieval Systems
In this type, GT principles are used to develop computer programs to assist in fixture
design[1]. It was found that modifying existing designs that are similar generates 70% of
fixture designs. In order to identify the similarities between fixture designs a special coding
system was developed based on part geometry, operational information, and fixturing
information. Although GT has been used in several manufacturing/design applications, it is
not versatile enough to all parts and products.
C. Automated Generation of Fixture Configuration
Goldberg developed a system called FixtureNet, which is an interactive computer-
aided fixture design for polygonal parts via the World Wide Web [7]. The user designs the
shape of the polygon needed through the World Wide Web, and the system constructs a
modular fixture consisting of a baseplate, three locators, and one clamp. The system can also
generate alternative solutions. The system is only limited to modular fixtures, many modules
are still missing, and is limited to 2–D polygonal shaped parts only.
D. Artificial Intelligence (AI) Based Systems
Quite a few AI based systems were found in the literature, but the most
comprehensible is the one developed by Roy and Liao [8]. Their system is based on a
blackboard framework to guarantee simultaneous access to the data by different
computational modules and maintain coherency and integrity of the processed information.
The blackboard system consists of three major components: knowledge sources (KS’s),
blackboard data structure, and control shell. The system is built using a generic blackboard
system, I-DEAS solid modeler, Concentra’s Concept Modeler, LISP and CLKIPs expert
systems, C, C++, and FORTRAN routines. Although the system provides a comprehensive
Proceedings of the 7th Cairo University International Conference on Mechanical Design &
Production, MDP-7, Cairo–Egypt, February 15- 17, 2000, pp. 251-260

package to solve the fixture design problems, it is found to be complicated, requiring

extensive maintenance, and is still of limited industrial use.
E. Advanced Analysis and Verification Based Computer Aided Fixture Design Systems
The system named FIXMA (FIXture Modeling & Analysis) that was developed at the
Machine Tool-Agile Manufacturing Research Institute (MATMRI) of the University of
Illinois at Urban-Champion, is a good example of this type of systems. This system features
some of the very important characteristics that are needed in fixture design software. It is
linked to one of the most comprehensive modeling package for cutting forces called
(EMSIM). It is also accessible via the Internet. FIXMA’s routines allow the designer to
predict the impact of several fixture design parameters on workpiece positioning error,
workpiece displacement within the machining fixture, and workpiece geometric variability.
The system offers three types of analysis modules namely kinematics restrain analysis
module to evaluate locator positioning scheme, restrain analysis module to evaluate the
clamping scheme, and clamp intensity analysis module to determine the minimum clamp
intensity required to hold the workpiece. A closed link is established with the cutting force
module to evaluate the minimum clamp intensity. Although this system is one of the most
comprehensive and practical systems reported in the literature, very little attention was paid
to the fixture design phase [9].
Sayeed and DeMeter [10] developed a software system for fixture design and
analysis, based on I-DEAS (Version 6), consisting of two main modules: design and analysis.
The interaction between the two modules is done through file transfer activities. The design
module writes a universal file for the workpiece. The analysis module extracts all the
necessary information through the data transfer module. They stated that this approach
decouples the analysis module from the CAD systems, thus permitting greater flexibility and
ease of implementation. The analysis module consists of three main sub-modules for
kinematic restrain analysis (based on the screw theory), total restrain analysis, and clamp
actuator intensity analysis. Once the designer has specified the locator contact regions, the
kinematic restrain analysis sub-module checks whether the part is kinematically restrained
(i.e. the workpiece can not displace and still in contact with its locators). If not, the locator
design activities are re-invoked. The total restrain analysis sub-module retrieves all the
necessary part information from the universal part file, and uses them to design of the clamp
contact regions. If the wrenches provided by the contact regions are capable of counteracting
any external wrench, the part is totally restrained. Finally, the clamp actuator intensity
analysis sub-module is invoked to determine the minimum clamping force.
From the discussion presented in this section, a comprehensive system for fixture
design and manufacture needs to be developed. Some desirable features in the system
include its adaptability to handle both dedicated and modular fixture designs, and its
integrability with advanced fixture analysis modules and virtual design test platforms such as
finite element, motion animation, and ergonomics.

3.1 Advanced Fixture Analysis

Fixture design analysis modules can be classified into pre-design and pots-design
analysis modules. Pre-design analysis targets the following functions:
? ? Selection of the positioning of the locating and clamping points and surfaces.
? ? Kinematic analysis to verify the locating scheme (screw theory is the best candidate to
perform this type of analysis [11]).
? ? Selection of the fixture components [1].
? ? Automatic assembly of the fixturing elements [12].
Post-design analysis is intended to evaluate the fixture design performance such as:
Proceedings of the 7th Cairo University International Conference on Mechanical Design &
Production, MDP-7, Cairo–Egypt, February 15- 17, 2000, pp. 251-260

?? Location accuracy analysis (Due to variations of workpiece dimensions and locator

positions [12]).
?? Clamping and machining stability under the varying machining condition [9, 10].
?? Workpiece deformation analysis (Optimization models in conjunction with FEA are used
to minimize workpiece deformation due to disturbing forces [13]).
?? Fixture stiffness under varying machining and clamping conditions (fixture stiffness can
be defined as the total deformation of a fixture components in a sensitive direction of
machining accuracy under the action of the machining and clamping forces [1]).
?? Tool path interference analysis (Interference between the fixture components and cutting
tool should be checked to avoid collision). A collision detection using spheres can be
used [14].

4.0 SYSTEM DESIGN CRITERIA AND GOALS

The following sections present goals, design criteria, conceptual system design and
the system logic flow diagram for the proposed CAFD system.

4.1 System Goals

Based on the literature survey of existing systems which are briefly described in
Section 3, the goals of the proposed system are:
? ? to provide a systematic approach to help in the design, analysis, and manufacturing of
machining fixtures using available CAE software tools,
? ? to reduce the product development cycle by automating the part/fixture assembly process,
? ? to reduce the design cycle time by automating the redundant and time-consuming
activities during the fixtures design process, and
? ? to develop a virtual platform for testing the practical aspects of fixture design such as ease
of part loading and unloading, accessibility, part jamming, ergonomic, and estimation of
the setup times.

4.2 System Design Criteria

Criterion 1 : Comprehensive Application
Although interactive computer-aided fixture design may not be academically
advanced, automated fixture design systems are not yet ready for industrial applications.
Commercial software will be used to perform specific tasks (if available). Otherwise
computer code will be written.
Criterion 2 : Generality
Although modular fixture designs may provide flexibility for fixture design, dedicated
fixture designs are sometimes needed to automate fixturing action and/or provide less
fixturing errors.
Criterion 3 : Performance Evaluation
Advanced analysis modules are needed and should be integrated within the
framework of the CAFD system to assess performance and/or suggest improvement.
Criterion 4: Adaptability
Changes in environment during machining due to the cutting action could lead to
deforming the part. The fixture should be designed to sense these changes and adapt the
fixturing actions accordingly.

4.3 System Conceptual Design and Logic Flow Diagram

Figures 1 and 2 show the conceptual design and the information logic flow among the
proposed modules of the system. As it can be seen from Figure 1, the system is built around
Proceedings of the 7th Cairo University International Conference on Mechanical Design &
Production, MDP-7, Cairo–Egypt, February 15- 17, 2000, pp. 251-260

I-DEAS solid modeling CAD/CAM system running under UNIX environment. The first
development step is taken by importing some fixture element libraries that are available from
different sources such as the one available by Carrlane manufacturing company [15]. The
second step is to develop the Application Program Interface (API). The API is created
utilizing Open I-DEAS (Open I-DEAS software will be used to customize, automate, and
integrate the analysis program applications and data translators with I-DEAS). Thus the API
will provide access to I-DEAS Open Link TM, I-DEAS Open GeometryTM , and I-DEAS
FEMTM modules. It will also allow client–server architecture interface using CORBA, thus
allowing for heterogeneous (systems written on different platforms such as Windows NT,
UNIX, etc.) communication applications.
The core programs of the system are developed using C and C++ programming
languages. The core programs are composed of several independent modules that are
integrated through the API platforms. This enables these core programs to be developed
efficiently without the burden of integration except in the final step. The core programs can
work independently to increase system efficiency, and they can be integrated to perform
accurate and reliable analysis.
Figure 2 shows the logic flow diagram of the system. As shown in the figure, input to
the system consists of the part design file, the machine tools, and the machining operations to
be performed. The system then determines the required locators and clamps, and by
searching the system libraries, the majority of these components are retrieved. If some
components are not found in the system libraries, the design module is invoked to design
these elements. If the designed components are to be manufactured, the manufacturing
module is invoked to generate the tool path. Finally, the part/fixture is assembled. The
designed fixture will be subjected to a series of analysis tests to assess the fixture
performance. If the fixture design is found to be acceptable, a virtual setup platform is set to
test the practical considerations such as animation of the fixturing motion, fixture
ergonomics, and estimation of the set up time required for the fixture to be set-up on the
machine.

4.4 Case Study

2,105 component IGEAS files from Carr Lane were imported into libraries within SDRC I-
DEAS tm Master series 6. The component had to be brought at the work plane to fix
translation errors (because of the different CAD platforms used to creat and import drawing).
Another intermediate software named SURFACERtm available from Imagewaretm 9.0 was
also used to help minimize the effect of this error. Figure 3 shows a fixture that was
assembled using Carr Lanetm tooling components. The workpiece was located on a
rectangular tooling plate (CL-MF40-0101: 19-7/8” x 15-7/8”). The 3-2-1 principle was used,
with 3 locators (CL-4-BND: 0.4998 DIA) assigned to the largest surface, which is the bottom
of the workpiece. The other three locators were used on the front and side surfaces of the
workpiece. These locators were placed in two short angle plates (CL-MF40-0501: 5-7/8”
high), which the two angle plated were mounted onto the rectangular tooling plate. The
configuration used restricted nine degrees of freedom, and satisfies the 3-2-1 principle.
To secure the workpiece while restricting another degree of freedom, a high nose
serrated adjustable clamp strap was used normal to the two locators on the rectangular tooling
plate.
Ten of the twelve degrees of freedom are satisfied. The other two degrees of
freedom are not need; first the top surface is needed to be machined, and second the
machining is assumed to be conducted on the width of the workpiece. Automation of the
fixture assembly process is still under development.
Proceedings of the 7th Cairo University International Conference on Mechanical Design &
Production, MDP-7, Cairo–Egypt, February 15- 17, 2000, pp. 251-260

5.0 CONCLUSION

The intent of this paper is to give an architecture framework for a computer-aided design
and manufacture system for machining fixtures. The conceptual design of the system is
based on decoupling the core programs from the CAD/CAM package to allow for greater
flexibility during the development phase. Taking advantage of the advanced Application
Program Interface (API) capabilities available in most of the new releases of CAD/CAM
systems, the API will handle most of the interface (integration) issues. The detailed
mathematical treatment of the analysis modules is still under preparation and will be
published soon.

6.0 ACKNOWLEDGMENT

Authors would like to acknowledge Mr. Scott from U-Michigan Dear-Born for his work
towrds the implemnetation of this system, and thank him for providing the case study .

7.0 REFERENCES

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4 Jiang, W., Wang, Z., Cai, Y., “Computer-Aided Group Fixture Design”, Annals of the
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Int. J. of Computer Application in Technology, Vol. 10, No.3/4, pp. 213-235, (1997).
6 Ma, W., Lei, Z., Rong, Y., “FIX-DES: A Computer-Aided Modular Fixture Configuration
Design System”, Int. J. Advanced Manufacturing. Technology, Vol. 14, N0. 14, pp. 21-
32, (1998).
7 Wagner, R., Castanotto, G., and Goldberg, K., “FixtureNet: Interactive Computer-Aided
Design via the World Wide Web,”, Int. J. Human-Computer Studies, Vol. 46, pp. 773-
788, (1997).
8 Roy U., and Liao, J., “Application of the Simultaneous Engineering Concept to the
Development of a Co-Operative Fixture Design System,”, Proceedings of the 31 st CIRP
Int. Seminar on Manufacturing Systems, pp. 199-204, (1998).
9 Melkote, S. N., Athavale, S. M., DeVor, R. E., Kapoor, S. G., and Burkey, J. J.,
“Prediction of the Reaction Force System for Machining Fixtures Based on Machining
Process Simulation,”, NAMRI/SME XXIII Conference, Houghton, MI, May 24, (1995).
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Int. J. Production Research, Vol. 32, No. 7, pp. 1655-1674, (1994).
11 Hargrove, S. K., Kusiak, A., 1994, “Computer-Aided Fixture Design: a Review,” Int. J.
Production Research, Vol. 32, No. 4, pp. 733-753.
Proceedings of the 7th Cairo University International Conference on Mechanical Design &
Production, MDP-7, Cairo–Egypt, February 15- 17, 2000, pp. 251-260

12 Wu, Y., Rong, K., Ma, W., LeClair, S. R., “Automated Modular Fixture Planning:
Accuracy, Clamping, and Accessibility Analysis,” MED-Vol. 6-2, Manufacturing Science
and Technology, Vol. 2, pp. 221-227, (1997).
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Optimization,” Int. J. of Machine Tools & Manufacture, Vol. 39, pp. 871-883, (1999).
14 Sandberg, D. W., “Collision Detection Using Sphere Approximation,” Proceedings of the
Int. Conf. on Robotics and Factories of the Future, pp. 465-460, (1987).
15 CarrLane Manufacturing Co., Modular Fixturing Handbook, CarrLane Mfg. Co., St.
Louis, Missouri, (1991).
16 Lee, S. H., Cutkosky, M. R., “Fixture Planning with Friction”, ASME transactions,
J. of Engineering for Industry, Vol. 113, pp. 320-327, (1991).

Fig. 1 System Conceptual Design

Proceedings of the 7th Cairo University International Conference on Mechanical Design &
Production, MDP-7, Cairo–Egypt, February 15- 17, 2000, pp. 251-260

Fig. 2 System Logic

Fig. 3 Case Study Implemented Into IDEAS Using Carr lane Componnet Library