Optimization of Machining Fixture for Aeronautical Thin-walled Components

The aim of this work has been the optimization of the fixtures performance used in thin-walled workpiece machining depending on the local rigidity characteristics of the component to be machined. An extensive topology optimization activity has been performed both on fixture-workpiece systems modelled with shell elements and on fixture-workpiece systems modelled with solid elements, varying the topology design variables and/or optimization constraints for each optimization problem, in order to provide a new design of fixture. Finally, a new blended Solid-Lattice design of the fixture, starting by the design topologically optimized, has been created. In this way, it has been possible to identify void regions in the design space, where the material can be removed, regions where solid material is needed, and regions where lattice structure is required. This has allowed to generate the optimal hybrid or blended solid-lattice design based on desired functionality of the part having as natural consequence the definition of a new method for fixtures design.