Numerical simulation of flexible fixture for multiaxis machining of bracket-type parts

Abstract The relevance of the study is driven by current trends in the development of the machine-building industry and the increasing demands for production efficiency. Under conditions of market globalization, intensified competition, and the need to ensure high product quality, there is a pressing necessity to transition to flexible manufacturing systems capable of promptly adapting to changes in the product mix and production volumes. One of the key elements enabling such flexibility is machine tooling devices, which ensure precise positioning, clamping, and orientation of workpieces during machining processes. This research becomes particularly pertinent in the context of the widespread implementation of multifunctional CNC machine tools and the advancement of smart manufacturing concepts. Under these circumstances, the development of flexible tooling systems capable of efficiently machining complex-shaped parts while minimizing setup times and auxiliary costs is of critical importance. Therefore, the aim of this article is to develop a highly flexible fixture design for machining bracket-type parts, enabling the implementation of locating-and-clamping approaches. As a result of the study, a flexible fixture configuration for machining bracket-type components has been designed, offering full tool accessibility, which allows the reduction of non-productive time losses and enables its application in robotic manufacturing cells while ensuring operational flexibility. The obtained results allowed the evaluation of the proposed fixture design through stress–strain state analysis, determination of natural vibration frequencies, dynamic response analysis, and the construction of amplitude-frequency characteristics. To assess its performance, the proposed design was compared with a conventional fixture. Graphical Abstract