Fixturing technology and system for thin-walled parts machining: a review

Abstract

During the overall processing of thin-walled parts (TWPs), the guaranteed capability of the machining process and quality is determined by fixtures. Therefore, reliable fixtures suitable for the structure and machining process of TWP are essential. In this review, the key role of fixtures in the manufacturing system is initially discussed. The main problems in machining and workholding due to the characteristics of TWP are then analyzed in detail. Afterward, the definition of TWP fixtures is reinterpreted from narrow and broad perspectives. Fixture functions corresponding to the issues of machining and workholding are then clearly stated. Fixture categories are classified systematically according to previous research achievements, and the operation mode, functional characteristics, and structure of each fixture are comprehensively described. The function and execution mode of TWP fixtures are then systematically summarized and analyzed, and the functions of various TWP fixtures are evaluated. Some directions for future research on TWP fixtures technology are also proposed. The main purpose of this review is to provide some reference and guidance for scholars to examine TWP fixtures.

Graphical abstract

Keywords

thin-walled part (TWP) / fixture / machining / fixture categories / fixture function

References

[1] Del Sol I , Rivero A , López de Lacalle L N , Gamez A J . Thin-wall machining of light alloys: a review of models and industrial approaches. Materials, 2019, 12(12): 2012

[2] Möhring H C , Wiederkehr P , Lerez C , Schmitz H , Goldau H , Czichy C . Sensor integrated CFRP structures for intelligent fixtures. Procedia Technology, 2016, 26: 120–128

[3] Xu C, Feng P F, Zhang J F, Yu D W, Wu Z J. Milling stability prediction for flexible workpiece using dynamics of coupled machining system. The International Journal of Advanced Manufacturing Technology, 2017, 90(9–12): 3217–3227

[4] Nguyen L T , Möhring H C . Stiffness and damping properties of a swing clamp: model and experiment. Procedia CIRP, 2017, 58: 299–304

[5] Möhring H C , Wiederkehr P . Intelligent fixtures for high performance machining. Procedia CIRP, 2016, 46: 383–390

[6] Brecher C , Esser M , Witt S . Interaction of manufacturing process and machine tool. CIRP Annals, 2009, 58(2): 588–607

[7] Hansel A , Yamazaki K , Konishi K . Improving CNC machine tool geometric precision using manufacturing process analysis techniques. Procedia CIRP, 2014, 14(1): 263–268

[8] Bakker O J , Papastathis T N , Popov A A , Ratchev S M . Active fixturing: literature review and future research directions. International Journal of Production Research, 2013, 51(11): 3171–3190

[9] Liu H B, Wu J X, Luo Q, Li T, Wang Y Q. Analysis of the effect of magnetorheological fluid excitation solidification clamping on modal parameters of thin-walled parts. Modern Manufacturing Engineering, 2019, 11: 107–112 (in Chinese)

[10] Budak E , Tunç L T , Alan S , Özgüven H N . Prediction of workpiece dynamics and its effects on chatter stability in milling. CIRP Annals, 2012, 61(1): 339–342

[11] Muhammad B B , Wan M , Liu Y , Yuan H . Active damping of milling vibration using operational amplifier circuit. Chinese Journal of Mechanical Engineering, 2018, 31(1): 90

[12] Díaz-Tena E , López de Lacalle Marcaide L N , Campa Gómez F J , Chaires Bocanegra D L . Use of magnetorheological fluids for vibration reduction on the milling of thin floor parts. Procedia Engineering, 2013, 63: 835–842

[13] Munoa J , Sanz-Calle M , Dombovari Z , Iglesias A , Pena-Barrio J , Stepan G . Tuneable clamping table for chatter avoidance in thin-walled part milling. CIRP Annals, 2020, 69(1): 313–316

[14] Zhang Z X , Zhang D H , Luo M , Wu B H . Research of machining vibration restraint method for compressor blade. Procedia CIRP, 2016, 56: 133–136

[15] Yi B , Wang J C . Mechanism clarification of mitigating welding induced buckling by transient thermal tensioning based on inherent strain theory. Journal of Manufacturing Processes, 2021, 68: 1280–1294

[16] Tadic B , Bogdanovic B , Jeremic B M , Todorovic P M , Luzanin O , Budak I , Vukelic D . Locating and clamping of complex geometry workpieces with skewed holes in multiple-constraint conditions. Assembly Automation, 2013, 33(4): 386–400

[17] Zhang F P, Wang L, Ni Y Z. Research on deformation based machining error analysis for thin walled parts. Modular Machine Tool & Automatic Manufacturing Technique, 2007, 10: 25–28 (in Chinese)

[18] Lu C, Huo D S, Wang Z Y. Assembly variation analysis of the aircraft panel in multi-stage assembly process with N-2-1 locating scheme. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 2019, 233(19–20): 6754–6773

[19] Schuster S , Steinzig M , Gibmeier J . Incremental hole drilling for residual stress analysis of thin walled components with regard to plasticity effects. Experimental Mechanics, 2017, 57(9): 1457–1467

[20] Wang T, Zha J, Jia Q, Chen Y L. Application of low-melting alloy in the fixture for machining aeronautical thin-walled component. The International Journal of Advanced Manufacturing Technology, 2016, 87(9–12): 2797–2807

[21] Cioată V G , Kiss I , Alexa V , Raţiu S A . Study of the contact forces between workpiece and fixture using dynamic analysis. Journal of Physics: Conference Series, 2020, 1426: 012040

[22] Liu H B, Wang C X, Han L S, Wang S J, Liu K, Wang Y Q. The influence of ice-based fixture on suppressing machining-induced deformation of cantilever thin-walled parts: a novel and green fixture. The International Journal of Advanced Manufacturing Technology, 2021, 117(1–2): 329–341

[23] Fei J X , Lin B , Xiao J L , Ding M , Yan S , Zhang X F , Zhang J . Investigation of moving fixture on deformation suppression during milling process of thin-walled structures. Journal of Manufacturing Processes, 2018, 32: 403–411

[24] Yan W M, Bi Y B, Qiao M J. Effect of positioning errors of frames on fuselage panel assembly deformation. Advances in Mechanical Engineering, 2016, 8(5): 1687814016650566

[25] Qi Z C, Zhang K F, Li Y, Cheng H. Analysis and optimization for locating errors of large wing panel during automatic drilling and riveting. Acta Aeronautica et Astronautica Sinica, 2015, 36(10): 3439–3449 (in Chinese)

[26] Aoyama T , Kakinuma Y . Development of fixture devices for thin and compliant workpieces. CIRP Annals, 2005, 54(1): 325–328

[27] Walczyk D F , Longtin R S . Fixturing of compliant parts using a matrix of reconfigurable pins. Journal of Manufacturing Science and Engineering, 2000, 122(4): 766–772

[28] Li F , Chen S J , Shi J B , Zhao Y . In-process control of distortion in wire and arc additive manufacturing based on a flexible multi-point support fixture. Science and Technology of Welding and Joining, 2019, 24(1): 36–42

[29] Craig O , Picavea J , Gameros A , Axinte D , Lowth S . Conformable fixture systems with flexure pins for improved workpiece damping. Journal of Manufacturing Processes, 2020, 50: 638–652

[30] Al-Habaibeh A , Gindy N , Parkin R M . Experimental design and investigation of a pin-type reconfigurable clamping system for manufacturing aerospace components. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2003, 217(12): 1771–1777

[31] He Z D, Tian D N, Yang J C, Yao Z H. Control and mechanical analysis of clamping deformation of thin-walled spherical shell workpiece during vacuum suction. Acta Armamentarii, 2017, 38(7): 1409–1415 (in Chinese)

[32] Qi R L , Mao X Y , Zhang K , Xia R B . Accurate clamping method of multipoint flexible fixture for large complex surface. Mathematical Problems in Engineering, 2021, 2021: 5568801

[33] Liu C Q, Hong J, Feng Y, Wang S F, Qiu Z H. Searching optimization algorithm for deformation control of aircraft thin-walled parts in multi-point flexible tooling system. Journal of Shanghai Jiao Tong University, 2013, 47(8): 1191–1197 (in Chinese)

[34] Yang J C, Zhang J F, Li J, Xie Q, Feng P F. Optimum design and mechanical analysis for flat fixture of thin-walled wafer workpiece under vacuum adsorption in ultra-precision machining. Journal of Xi’an Jiaotong University, 2019, 53(4): 31–37 (in Chinese)

[35] Rubio-Mateos A , Casuso M , Rivero A , Ukar E , Lamikiz A . Vibrations characterization in milling of low stiffness parts with a rubber-based vacuum fixture. Chinese Journal of Aeronautics, 2021, 34(6): 54–66

[36] Rubio-Mateos A , Rivero A , Ukar E , Lamikiz A . Influence of elastomer layers in the quality of aluminum parts on finishing operations. Metals, 2020, 10(2): 289

[37] Kihlman H, Engstrom M. Flexapods—Flexible Tooling at SAAB For Building the NEURON Aircraft. SAE Technical Paper 2010-01-1871, 2010

[38] Kihlman H, Engstrӧm M. Affordable Reconfigurable Tooling. SAE Technical Paper 2002-01-2645, 2002

[39] Zhang H B , Zheng L Y , Chen X W , Huang H J . A novel reconfigurable assembly jig based on stable agile joints and adaptive positioning-clamping bolts. Procedia CIRP, 2016, 44: 316–321

[40] Jonsson M , Kihlman H , Ossbahr G . Coordinate controlled fixturing for affordable reconfigurable tooling. In: Proceedings of the 2nd CIRP Conference on Assembly Technologies and Systems. Toronto: CIRP, 2008, 1–11

[41] Cioată V G , Alexa V , Raţiu S A . Study of the stiffness of modular fixtures using the finite element method. IOP Conference Series: Materials Science and Engineering, 2018, 393: 012036

[42] Wang H , Rong Y M , Li H , Shaun P . Computer aided fixture design: recent research and trends. Computer-Aided Design, 2010, 42(12): 1085–1094

[43] Croppi L , Grossi N , Scippa A , Campatelli G . Fixture optimization in turning thin-wall components. Machines, 2019, 7(4): 68

[44] Nee A Y C, Whybrew K, Kumar A S. Advanced Fixture Design for FMS. London: Springer, 1995

[45] Bao Y, Dong Z G, Zhu X, Wang C, Guo D, Kang R. Review on support technology for mirror milling of aircraft skin. Acta Aeronautica et Astronautica Sinica, 2018, 39(4): 021817 (in Chinese)

[46] Bao Y , Kang R K , Dong Z G , Zhu X L , Wang C R , Guo D M . Multipoint support technology for mirror milling of aircraft skins. Materials and Manufacturing Processes, 2018, 33(9): 996–1002

[47] Xiao J L, Zhang Q Y, Liu H T, Huang T, Shan X L. Research on vibration suppression by a multi-point flexible following support head in thin-walled parts mirror milling. The International Journal of Advanced Manufacturing Technology, 2020, 106(7–8): 3335–3344

[48] Veeramani S , Muthuswamy S . Hybrid type multi-robot path planning of a serial manipulator and SwarmItFIX robots in sheet metal milling process. Complex & Intelligent Systems, 2022, 8: 2937–2954

[49] de Leonardo L , Zlatanov D , Zoppi M , Molfino R . Design of the locomotion and docking system of the SwarmItFIX mobile fixture agent. Procedia Engineering, 2013, 64: 1416–1425

[50] Sagar K , de Leonardo L , Molfino R , Zielińska T , Zieliński C , Zlatanov D , Zoppi M . The swarmItFix pilot. Procedia Manufacturing, 2017, 11: 413–422

[51] Liu C, Sun J, Li Y L, Li J F. Investigation on the milling performance of titanium alloy thin-walled part with air jet assistance. The International Journal of Advanced Manufacturing Technology, 2018, 95(5–8): 2865–2874

[52] Rajaratnam N , Albers C . Water distribution in very high velocity water jets in air. Journal of Hydraulic Engineering, 1998, 124(6): 647–650

[53] Wang Y Q , Gan Y Q , Liu H B , Han L S , Wang J Y , Liu K . Surface quality improvement in machining an aluminum honeycomb by ice fixation. Chinese Journal of Mechanical Engineering, 2020, 33(1): 20

[54] Mironova A , Mercorelli P , Zedler A . Lyapunov control strategy for thermoelectric cooler activating an ice-clamping system. Journal of Thermal Science and Engineering Applications, 2018, 10(4): 041020

[55] Mironova A , Mercorelli P , Zedler A . Thermal disturbances attenuation using a Lyapunov controller for an ice-clamping device actuated by thermoelectric coolers. Thermal Science and Engineering Progress, 2018, 6: 290–299

[56] Mironova A. Effects of the influence factors in adhesive workpiece clamping with ice: experimental study and performance evaluation for industrial manufacturing applications. The International Journal of Advanced Manufacturing Technology, 2018, 99(1–4): 137–160

[57] Zha J , Chu J , Li Y P , Chen Y L . Thin-walled double side freeform component milling process with paraffin filling method. Micromachines, 2017, 8(11): 332

[58] Ge M J , Sun J , Li J F . Study on processing property of thin-walled titanium alloy component with paraffin reinforcement. Advanced Materials Research, 2011, 325: 321–326

[59] Gao B, Sun J, Li J F. Research on machining accuracy in milling Ti6Al4V thin-walled component with paraffin reinforcement. Applied Mechanics and Materials, 2012, 268–270: 504–509

[60] Saito A , Kato S , Nagao M . Supporting method for thin parts having curved surfaces-improvement of end milling accuracy by using low-melting point alloy and elastomer support. International Journal of Automotive Technology, 2019, 13(1): 92–100

[61] Lee E , Sarma S E . Reference free part encapsulation: materials, machines and methods. Journal of Manufacturing Systems, 2007, 26(1): 22–36

[62] Lee E , Valdivia P , Fan W , Sarma S E . The process window for reference free part encapsulation. Journal of Manufacturing Science and Engineering, 2002, 124(2): 358–368

[63] Lee E, Sarma S E, Alvarado P V Y. Simulations and Experiments in Encapsulation Fixturing. SME Technical Paper MS01-307, 2001

[64] Liu H B, Wang J P, Luo Q, Bo Q L, Li T, Wang Y Q. Effect of controllable magnetic field-induced MRF solidification on chatter suppression of thin-walled parts. The International Journal of Advanced Manufacturing Technology, 2020, 109(9–12): 2881–2890

[65] Ma J J , Zhang D H , Wu B H , Luo M , Chen B . Vibration suppression of thin-walled workpiece machining considering external damping properties based on magnetorheological fluids flexible fixture. Chinese Journal of Aeronautics, 2016, 29(4): 1074–1083

[66] Liu G, Ke Y L. Study on paper honeycomb position fixation method. Journal of Zhejiang University (Engineering Science), 2004, 38(4): 501–504 (in Chinese)

[67] LiuGKeY L. Study on rudder clamping method of paper honeycomb. Journal of Aeronautical Materials, 2004, 24(5): 44–48, 52 (in Chinese)

[68] Walczyk D , Munro C . Modeling and analysis of an active reconfigurable fixturing device using a bed of pins lowered on a moving platen. Journal of Manufacturing Science and Engineering, 2009, 131(2): 021009

[69] Youcef-Toumi K , Buitrago J H . Design and implementation of robot-operated adaptable and modular fixtures. Robotics and Computer-Integrated Manufacturing, 1989, 5(4): 343–356

[70] Sela M N , Gaudry O , Dombre E , Benhabib B . A reconfigurable modular fixturing system for thin-walled flexible objects. The International Journal of Advanced Manufacturing Technology, 1997, 13(9): 611–617

[71] Bejlegaard M , ElMaraghy W , Brunoe T D , Andersen A L , Nielsen K . Methodology for reconfigurable fixture architecture design. CIRP Journal of Manufacturing Science and Technology, 2018, 23: 172–186

[72] Ngoi B K A , Tay M L , Wong C S . Development of an automated fixture set-up system for inspection. The International Journal of Advanced Manufacturing Technology, 1997, 13(5): 342–349

[73] Erdem I , Levandowski C , Berlin C , Kihlman H , Stahre J . A novel comparative design procedure for reconfigurable assembly fixtures. CIRP Journal of Manufacturing Science and Technology, 2017, 19: 93–105

[74] Ou Y J, Yin G F, Zhou C C. Case-based reasoning auto-assembly technology of modular fixture. Computer Integrated Manufacturing Systems, 2011, 17(11): 2426–2431 (in Chinese)

[75] Vasundara M, Padmanaban K P. Recent developments on machining fixture layout design, analysis, and optimization using finite element method and evolutionary techniques. The International Journal of Advanced Manufacturing Technology, 2014, 70(1–4): 79–96

[76] Cecil J . Computer aided fixture design: using information intensive function models in the development of automated fixture design systems. Journal of Manufacturing Systems, 2002, 21(1): 58–71

[77] Molfino R, Zoppi M, Zlatanov D. Reconfigurable swarm fixtures. In: Proceedings of 2009 ASME/IFToMM International Conference on Reconfigurable Mechanisms and Robots. 2009, 730–735

[78] Gameros A , Lowth S , Axinte D , Nagy-Sochacki A , Craig O , Siller H R . State-of-the-art in fixture systems for the manufacture and assembly of rigid components: a review. International Journal of Machine Tools and Manufacture, 2017, 123: 1–21

[79] Bi Z M , Zhang W J . Flexible fixture design and automation: review, issues and future directions. International Journal of Production Research, 2001, 39(13): 2867–2894

[80] Gonzalo O , Seara J M , Guruceta E , Izpizua A , Esparta M , Zamakona I , Uterga N , Aranburu A , Thoelen J . A method to minimize the workpiece deformation using a concept of intelligent fixture. Robotics and Computer-Integrated Manufacturing, 2017, 48: 209–218

[81] Asada H , By A . Kinematic analysis of workpart fixturing for flexible assembly with automatically reconfigurable fixtures. IEEE Journal on Robotics and Automation, 1985, 1(2): 86–94

[82] Wen T, Hu Q X. Automatic planning approach of auxiliary clamping points of rapid fixture in thin-walled parts. Advanced Materials Research, 2010, 139–141: 1229–1232

[83] Fan L , Senthil Kumar A . Development of robust fixture locating layout for machining workpieces. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2010, 224(12): 1792–1803

[84] Sundararaman K A, Guharaja S, Padmanaban K P, Sabareeswaran M. Design and optimization of machining fixture layout for end-milling operation. The International Journal of Advanced Manufacturing Technology, 2014, 73(5–8): 669–679

[85] Siva Kumar K , Paulraj G . Genetic algorithm based deformation control and clamping force optimisation of workpiece fixture system. International Journal of Production Research, 2011, 49(7): 1903–1935

[86] Krishnakumar K , Melkote S N . Machining fixture layout optimization using the genetic algorithm. International Journal of Machine Tools and Manufacture, 2000, 40(4): 579–598

[87] Vallapuzha S , De Meter E C , Choudhuri S , Khetan R P . An investigation of the effectiveness of fixture layout optimization methods. International Journal of Machine Tools and Manufacture, 2002, 42(2): 251–263

[88] Merlo A , Ricciardi D , Salvi E , Fantinati D , Iorio E . Novel adaptive fixturing for thin walled aerospace parts. IOP Conference Series: Materials Science and Engineering, 2011, 26(1): 012020

[89] Liu G Q, Zhao Z C, Fu Y C, Xu J H, Li Z Q. Deformation analysis and error prediction in machining of thin-walled honeycomb-core sandwich structural parts. The International Journal of Advanced Manufacturing Technology, 2018, 95(9–12): 3875–3886

[90] Wan M , Dang X B , Zhang W H , Yang Y . Chatter suppression in the milling process of the weakly-rigid workpiece through a moving fixture. Journal of Materials Processing Technology, 2022, 299: 117293

[91] Li H , Chen W F , Shi S J . Design and application of flexible fixture. Procedia CIRP, 2016, 56: 528–532

[92] Bao Y, Kang R K, Dong Z G, Zhu X L, Wang C R, Guo D M. Model for surface topography prediction in mirror-milling of aircraft skin parts. The International Journal of Advanced Manufacturing Technology, 2018, 95(5–8): 2259–2268

[93] Wang X Z , Li Z L , Bi Q Z , Zhu L M , Ding H . An accelerated convergence approach for real-time deformation compensation in large thin-walled parts machining. International Journal of Machine Tools and Manufacture, 2019, 142: 98–106

[94] Xiao J L , Zhao S L , Guo H , Huang T , Lin B . Research on the collaborative machining method for dual-robot mirror milling. The International Journal of Advanced Manufacturing Technology, 2019, 105(10): 4071–4084

[95] Gandhi M V , Thompson B S . Phase-change fixturing for flexible manufacturing system. Journal of Manufacturing Systems, 1985, 4(1): 29–39

[96] Sarma S E , Wright P K . Reference free part encapsulation: a new universal fixturing concept. Journal of Manufacturing Systems, 1997, 16(1): 35–47

[97] Ahn S H , Wright P K . Reference free part encapsulation (RFPE): an investigation of material properties and the role of RFPE in a taxonomy of fixturing systems. Journal of Manufacturing Systems, 2002, 21(2): 101–110

[98] Yang J G, Xiang Q, Wang Q X. Development and application for reference free part encapsulation fixturing. Computer Integrated Manufacturing Systems, 2002, 8(3): 243–247 (in Chinese)

[99] Liu G, Ke Y L. Study on clamping method for paper honeycomb based on magnetic field and friction principle. Journal of Materials Processing Technology, 2007, 190(1–3): 65–72

[100] Pei P , Peng Y B . Constitutive modeling of magnetorheological fluids: a review. Journal of Magnetism and Magnetic Materials, 2022, 550: 169076

[101] Aziz M A , Aminossadati S M . State-of-the-art developments of bypass magnetorheological (MR) dampers: a review. Korea-Australia Rheology Journal, 2021, 33(3): 225–249

[102] Aoyama T . Development of gel structured electrorheological fluids and their application for the precision clamping mechanism of aerostatic sliders. CIRP Annals, 2004, 53(1): 325–328

[103] Aoyama T , Inasaki I . Application of electrorheological fluid dampers to machine tool elements. CIRP Annals, 1997, 46(1): 309–312

[104] Yakoh T, Aoyama T. Application of electro-rheological fluids to flexible mount and damper devices. In: Proceedings of 2000 the 26th Annual Conference of the IEEE Industrial Electronics Society. 2000, 3(1–4): 1815–1820

[105] Gulley G L , Tao R . Static shear stress of electrorheological fluids. Physical Review E, 1993, 48(4): 2744

[106] Yu J Y . Study on electrorheological fluid damper for application in machining chatter control. Chinese Journal of Mechanical Engineering (English Edition), 2003, 16(1): 13

[107] Korobko E V , Kolik V L , Korobko Y O . Adaptive electrorheological layer for precision control of thin-wall constructions. Smart Structures and Materials 2003: Damping and Isolation. SPLE, 2003, 5052: 445–450

[108] Kakinuma Y , Aoyama T , Anzai H . Application of the electro-rheological gel to fixture devices for micro milling processes. Journal of Advanced Mechanical Design, Systems and Manufacturing, 2007, 1(3): 387–398

[109] Kakinuma Y , Aoyama T , Anzai H , Sakurai H , Isobe K , Tanaka K . Application of ER gel with variable friction surface to the clamp system of aerostatic slider. Precision Engineering, 2006, 30(3): 280–287

[110] Tang X , Zhang X , Tao R . Flexible fixture device with magneto-rheological fluids. Journal of Intelligent Material Systems and Structures, 1999, 10(9): 690–694

[111] Rong Y , Tao R , Tang X . Flexible fixturing with phase-change materials. Part 1. Experimental study on magnetorheological fluids. The International Journal of Advanced Manufacturing Technology, 2000, 16(11): 822–829

[112] Lange N , Gandhi M V , Thompson B S , Desal D J . An experimental evaluation of the capabilities of a fluidised-bed fixturing system. The International Journal of Advanced Manufacturing Technology, 1989, 4(2): 192–206

[113] Thompsons B S , Gandhi M V , Desai D J . Workpiece-fixture interactions in a compacted fluidized-bed fixture under various loading conditions. International Journal of Production Research, 1989, 27(2): 229–246

[114] Abou-Hanna J , Okumura K , McGreevy T . Dynamic behavior and creep characteristics of flexible particulate bed fixtures. Journal of Manufacturing Systems, 1993, 12(6): 496–505

[115] Abou-Hanna J , Okumura K , McGreevy T . Experimental study of static and dynamic rigidities of flexible particulate bed fixtures under external vertical and torque loads. Journal of Manufacturing Systems, 1994, 13(3): 177–189

[116] Ke Y L , Liu G . Attractive fixture system based on magnetic field and friction force for numerically controlled machining of paper honeycomb core. Journal of Manufacturing Science and Engineering, 2005, 127(4): 901–906

[117] Liu G, Feng Z H, Zhang M, Ke Y L. Design of compacting and iron powder filling device in paper honeycomb parts clamping system. Acta Aeronautica et Astronautica Sinica, 2012, 33(10): 1938–1946 (in Chinese)

[118] Liu G, Liu C, Zhang M, Ke Z Z, Ke Y L, Li W Q, Zhao X A. Separating mechanism design for iron powder and paper scraps based on magnetic force. Journal of Zhejiang University (Engineering Science), 2013, 47(7): 1267–1273 (in Chinese)

[119] Henriksen E K. Jig and Fixture Design Manual. South Norwalk: Industrial Press, 1973

[120] Rong Y M, Huang S H, Hou Z K. Advanced Computer-Aided Fixture Design. New York: Elsevier, 2005

[121] Nee A Y C, Kumar A S, Tao Z J. An Advanced Treatise on Fixture Design and Planning. Singapore: World Scientific, 2004

[122] Cai W , Hu S J , Yuan J X . Deformable sheet metal fixturing: principles, algorithms, and simulations. Journal of Manufacturing Science and Engineering, 1996, 118(3): 318–324

[123] Wang J C , Rashed S , Murakawa H . Mechanism investigation of welding induced buckling using inherent deformation method. Thin-Walled Structures, 2014, 80: 103–119

[124] Zhang F P, Sun H F, Butt S. Minimum normal force principle based quantitative optimization of clamping forces for thin walled part. Journal of Beijing Institute of Technology, 2008, 17(2): 148–152 (in Chinese)

[125] Xiong C H , Wang M Y , Xiong Y L . On clamping planning in workpiece-fixture systems. IEEE Transactions on Automation Science and Engineering, 2008, 5(3): 407–419

[126] Zhang K Y, Wu D B, Wang J. Research on machining fixture layout optimization for near-net-shaped jet engine blade. In: Proceedings of 2019 the 5th International Conference on Mechanical Engineering and Automation Science (ICMEAS 2019). 2019, 692: 198–203 (in Chinese)

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

[128] Boyle I , Rong Y M , Brown D C . A review and analysis of current computer-aided fixture design approaches. Robotics and Computer-Integrated Manufacturing, 2011, 27(1): 1–12

[129] Satyanarayana S , Melkote S N . Finite element modeling of fixture-workpiece contacts: single contact modeling and experimental verification. International Journal of Machine Tools and Manufacture, 2004, 44(9): 903–913

[130] Parvaz H , Nategh M J . Development of locating system design module for freeform workpieces in computer-aided fixture design platform. Computer-Aided Design, 2018, 104: 1–14

[131] Pelinescu D, Wang M Y. Multi-objective optimal fixture layout design in a discrete domain. In: Proceedings of 2001 IEEE/ASME International Conference on Advanced Intelligent Mechatronics. 2001, 1: 201–206

[132] Kaya N . Machining fixture locating and clamping position optimization using genetic algorithms. Computers in Industry, 2006, 57(2): 112–120

[133] Pelinescu D M, Wang M Y. Multi-objective optimal fixture layout design. Robotics and Computer-Integrated Manufacturing, 2002, 18(5–6): 365–372

[134] Rai J K , Xirouchakis P . Finite element method based machining simulation environment for analyzing part errors induced during milling of thin-walled components. International Journal of Machine Tools and Manufacture, 2008, 48(6): 629–643

[135] Kulankara K , Satyanarayana S , Melkote S N . Iterative fixture layout and clamping force optimization using the genetic algorithm. Journal of Manufacturing Science and Engineering, 2002, 124(1): 119–125

[136] Padmanaban K P, Arulshri K P, Prabhakaran G. Machining fixture layout design using ant colony algorithm based continuous optimization method. The International Journal of Advanced Manufacturing Technology, 2009, 45(9–10): 922–934

[137] Wang S S , Jia Z Y , Lu X H , Zhang H X , Zhang C , Liang S Y . Simultaneous optimization of fixture and cutting parameters of thin-walled workpieces based on particle swarm optimization algorithm. Simulation, 2018, 94(1): 67–76

[138] Pan M H , Tang W C , Xing Y , Ni J . The clamping position optimization and deformation analysis for an antenna thin wall parts assembly with ASA, MIGA and PSO algorithm. International Journal of Precision Engineering and Manufacturing, 2017, 18(3): 345–357

[139] Rex F M T , Ravindran D . An integrated approach for optimal fixture layout design. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2017, 231(7): 1217–1228

[140] Do M D , Son Y , Choi H J . Optimal workpiece positioning in flexible fixtures for thin-walled components. Computer-Aided Design, 2018, 95: 14–23

[141] Wang Z Q, Li C, Yang B, Yang Y. Fixture locating layout optimization of curved thin-walled parts based on FPA. China Mechanical Engineering, 2017, 28(18): 2231–2236 (in Chinese)

[142] Prabhaharan G, Padmanaban K P, Krishnakumar R. Machining fixture layout optimization using FEM and evolutionary techniques. The International Journal of Advanced Manufacturing Technology, 2007, 32(11–12): 1090

[143] Qin G H, Wang Z K, Wu Z X, Lu Y M. A planning method of fixturing layout for complex workpieces based on surface discretization and genetic algorithm. Journal of Mechanical Engineering, 2016, 52(13): 195–203 (in Chinese)

[144] Liu C Q , Li Y G , Shen W M . A real time machining error compensation method based on dynamic features for cutting force induced elastic deformation in flank milling. Machining Science and Technology, 2018, 22(5): 766–786

[145] Liu S M , Shao X D , Ge X B , Wang D . Simulation of the deformation caused by the machining cutting force on thin-walled deep cavity parts. The International Journal of Advanced Manufacturing Technology, 2017, 92(9): 3503–3517

[146] Ratchev S , Liu S , Huang W , Becker A A . An advanced FEA based force induced error compensation strategy in milling. International Journal of Machine Tools and Manufacture, 2006, 46(5): 542–551

[147] Huang W W , Zhang Y , Zhang X Q , Zhu L M . Wall thickness error prediction and compensation in end milling of thin-plate parts. Precision Engineering, 2020, 66: 550–563

[148] Ge G Y, Du Z C, Yang J H. Rapid prediction and compensation method of cutting force-induced error for thin-walled workpiece. The International Journal of Advanced Manufacturing Technology, 2020, 106(11–12): 5453–5462

[149] Zhao X , Zheng L Y , Zhang Y H . Online first-order machining error compensation for thin-walled parts considering time-varying cutting condition. Journal of Manufacturing Science and Engineering, 2022, 144(2): 021006

[150] Hao X Z , Li Y G , Zhao Z W , Liu C Q . Dynamic machining process planning incorporating in-process workpiece deformation data for large-size aircraft structural parts. International Journal of Computer Integrated Manufacturing, 2019, 32(2): 136–147

[151] Fan W , Zheng L Y , Ji W , Xu X , Wang L H , Zhao X . A data-driven machining error analysis method for finish machining of assembly interfaces of large-scale components. Journal of Manufacturing Science and Engineering, 2021, 143(4): 041010

[152] Gao Y Y, Ma J W, Jia Z Y, Wang F J, Si L K, Song D N. Tool path planning and machining deformation compensation in high-speed milling for difficult-to-machine material thin-walled parts with curved surface. The International Journal of Advanced Manufacturing Technology, 2016, 84(9–12): 1757–1767

[153] Li Z L , Zhu L M . Compensation of deformation errors in five-axis flank milling of thin-walled parts via tool path optimization. Precision Engineering, 2019, 55: 77–87

[154] Koike Y , Matsubara A , Yamaji I . Design method of material removal process for minimizing workpiece displacement at cutting point. CIRP Annals, 2013, 62(1): 419–422

[155] Si H , Wang L P . Error compensation in the five-axis flank milling of thin-walled workpieces. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2019, 233(4): 1224–1234

[156] Wang J , Ibaraki S , Matsubara A . A cutting sequence optimization algorithm to reduce the workpiece deformation in thin-wall machining. Precision Engineering, 2017, 50: 506–514

[157] Alexander I , Vladimir G , Petr P , Mihail K , Yuriy I , Andrey V . Machining of thin-walled parts produced by additive manufacturing technologies. Procedia CIRP, 2016, 41: 1023–1026

[158] Campa F J , López de Lacalle L N , Celaya A . Chatter avoidance in the milling of thin floors with bull-nose end mills: model and stability diagrams. International Journal of Machine Tools and Manufacture, 2011, 51(1): 43–53

[159] Wan X J , Zhang Y , Huang X D . Investigation of influence of fixture layout on dynamic response of thin-wall multi-framed work-piece in machining. International Journal of Machine Tools and Manufacture, 2013, 75: 87–99

[160] Matsubara A , Taniyama Y , Wang J , Kono D . Design of a support system with a pivot mechanism for suppressing vibrations in thin-wall milling. CIRP Annals, 2017, 66(1): 381–384

[161] Jia J J, Niu J B, Sun Y W. Dynamics modeling and stability improvement in the machining of thin-walled workpiece with force-tunable pneumatic fixture. The International Journal of Advanced Manufacturing Technology, 2021, 117(3–4): 1029–1043

[162] Munoa J , Iglesias A , Olarra A , Dombovari Z , Zatarain M , Stepan G . Design of self-tuneable mass damper for modular fixturing systems. CIRP Annals, 2016, 65(1): 389–392

[163] Wang M , Fei R Y . Chatter suppression based on nonlinear vibration characteristic of electrorheological fluids. International Journal of Machine Tools and Manufacture, 1999, 39(12): 1925–1934

[164] Yuan H, Wan M, Yang Y, Zhang W H. A tunable passive damper for suppressing chatters in thin-wall milling by considering the varying modal parameters of the workpiece. The International Journal of Advanced Manufacturing Technology, 2019, 104(9–12): 4605–4616

[165] Kolluru K , Axinte D , Becker A . A solution for minimising vibrations in milling of thin walled casings by applying dampers to workpiece surface. CIRP Annals, 2013, 62(1): 415–418

[166] Yang Y Q , Xu D D , Liu Q . Vibration suppression of thin-walled workpiece machining based on electromagnetic induction. Materials and Manufacturing Processes, 2015, 30(7): 829–835

[167] Butt M A , Yang Y Q , Pei X Z , Liu Q . Five-axis milling vibration attenuation of freeform thin-walled part by eddy current damping. Precision Engineering, 2018, 51: 682–690

[168] Kolluru K , Axinte D . Novel ancillary device for minimising machining vibrations in thin wall assemblies. International Journal of Machine Tools and Manufacture, 2014, 85: 79–86

[169] Fan W , Zheng L Y , Ji W , Zhao X , Wang L H , Yang Y Q . Eddy current-based vibration suppression for finish machining of assembly interfaces of large aircraft vertical tail. Journal of Manufacturing Science and Engineering, 2019, 141(7): 071012

[170] Bae J S , Hwang J H , Roh J H , Kim J H , Yi M S , Lim J H . Vibration suppression of a cantilever beam using magnetically tuned-mass-damper. Journal of Sound and Vibration, 2012, 331(26): 5669–5684

[171] Bae J S , Hwang J H , Kim J H , Lim J H . Vibration suppression of a cantilever beam using MTMD. Transactions of the Korean Society for Noise and Vibration Engineering, 2011, 21(12): 1091–1097

[172] Rimašauskienė R , Jūrėnas V , Radzienski M , Rimašauskas M , Ostachowicz W . Experimental analysis of active–passive vibration control on thin-walled composite beam. Composite Structures, 2019, 223: 110975

[173] Singh R , Deiab I M . Non-contact auxiliary fixture for machining stability improvement of thin flexible workpieces using eddy currents. International Journal of Interactive Design and Manufacturing, 2019, 13(2): 423–440

[174] Luo Q , Wang Y Q , Liu H B , Wang J P , Gan Y Q , Li T . Static response analysis of shallow spherical shell under local support of magnetorheological fluid (MRF). Thin-Walled Structures, 2021, 169: 108470

[175] Rezaei Aderiani A, Wärmefjord K, Söderberg R, Lindkvist L, Lindau B. Optimal design of fixture layouts for compliant sheet metal assemblies. The International Journal of Advanced Manufacturing Technology, 2020, 110(7–8): 2181–2201

[176] Nee A Y C , Kumar A S , Tao Z J . An intelligent fixture with a dynamic clamping scheme. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2000, 214(3): 183–196

[177] Wang Y F , Wong Y S , Fuh J Y H . Off-line modelling and planning of optimal clamping forces for an intelligent fixturing system. International Journal of Machine Tools and Manufacture, 1999, 39(2): 253–271

[178] Sallese L , Grossi N , Tsahalis J , Scippa A , Campatelli G . Intelligent fixtures for active chatter control in milling. Procedia CIRP, 2016, 55: 176–181

[179] Abele E , Hanselka H , Haase F , Schlote D , Schiffler A . Development and design of an active work piece holder driven by piezo actuators. Production Engineering, 2008, 2(4): 437–442

[180] Li Y G , Liu C Q , Hao X Z , Gao J X , Maropoulos P G . Responsive fixture design using dynamic product inspection and monitoring technologies for the precision machining of large-scale aerospace parts. CIRP Annals, 2015, 64(1): 173–176

[181] Wang S Y, Song Q H, Liu Z Q. Vibration suppression of thin-walled workpiece milling using a time-space varying PD control method via piezoelectric actuator. The International Journal of Advanced Manufacturing Technology, 2019, 105(7–8): 2843–2856

[182] Rubio-Ramirez C , Giarollo D F , Mazzaferro J E , Mazzaferro C P . Prediction of angular distortion due GMAW process of thin-sheets Hardox 450® steel by numerical model and artificial neural network. Journal of Manufacturing Processes, 2021, 68: 1202–1213

Nomenclature

ACA	Ant colony algorithm
AF	Adsorption fixture
APCM	Authentic phase change material
ART	Affordable reconfigurable tooling
BF	Bespoke fixture
CF	Conformable fixture
DOF	Degree of freedom
ECD	Eddy current damping
ERF	Electrorheological fluid
FEA	Finite element analysis
FMSF	Flexible multi-point support fixture
FPA	Flower pollination algorithm
FUF	Follow-up fixture
GA	Genetic algorithm
IBF	Ice-based fixture
IPBF	Iron-powder-based fixture
JS	Jet support
LMA	Low-melting alloy
LN2	Liquid nitrogen
MF	Modular fixture
MRF	Magnetorheological fluid
MRS	Multi-robot system
MS	Mirror support
NNA	Neural network algorithm
PBD	Particle-based damping
PCM	Phase change material
PF	Paraffin fixture
PFB	Particulate fluidized bed
PPCM	Pseudo phase change material
PSA	Particle swarm algorithm
RF	Reconfigurable fixture
RFPE	Reference free part encapsulation
TMD	Tuned mass damping
TWP	Thin-walled part
VAF	Vacuum adsorption fixture

Acknowledgements

The authors gratefully acknowledge the financial support from the National Natural Science Foundation of China (Grant Nos. U20B2033 and 51975093), and the Natural Science Foundation of Liaoning, China (Grant No. 2020-YQ-09).

Declaration of Competing Interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Open Access

This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution, and reproduction in any medium or format as long as appropriate credit is given to the original author(s) and source, a link to the Creative Commons license is provided, and the changes made are indicated.

The images or other third-party material in this article are included in the article’s Creative Commons license, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons license and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.

Visit http://creativecommons.org/licenses/by/4.0/ to view a copy of this license.

RIGHTS & PERMISSIONS

2022 The Author(s). This article is published with open access at link.springer.com and journal.hep.com.cn