Methodical approach to fixture design in the milling of thin-walled mechanical components
The milling of thin-walled mechanical components presents unique challenges due to their low structural stiffness and high susceptibility to elastic deformation under machining and clamping forces. This study proposes a methodical approach to the design and validation of a specialized fixture system...
Saved in:
| Main Authors: | , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-09-01
|
| Series: | Results in Engineering |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2590123025025873 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1849419709390258176 |
|---|---|
| author | Nguyen Thi Anh Tran Thanh Tung |
| author_facet | Nguyen Thi Anh Tran Thanh Tung |
| author_sort | Nguyen Thi Anh |
| collection | DOAJ |
| description | The milling of thin-walled mechanical components presents unique challenges due to their low structural stiffness and high susceptibility to elastic deformation under machining and clamping forces. This study proposes a methodical approach to the design and validation of a specialized fixture system tailored for such thin-walled geometries, with a focus on motorcycle gearbox housings. These components often feature complex contours, irregular wall thicknesses, and functional surfaces that demand high dimensional precision. To address these requirements, the proposed fixture incorporates profile-matching jaws and pneumatic clamping to ensure uniform load distribution, reduce deflection, and prevent localized stress on delicate wall sections. The fixture design was evaluated through finite element analysis (FEA) to assess stress distribution and displacement behavior under operational loads. Experimental validation confirmed that the fixture maintained positional accuracy, suppressed vibration, and achieved consistent machining quality. The results demonstrate the effectiveness of the proposed fixture system in improving repeatability, surface finish, and structural integrity during the milling of thin-walled components, offering a viable solution for high precision, high volume production. |
| format | Article |
| id | doaj-art-03cbecdcb388433db0b2dd27ee209edc |
| institution | Kabale University |
| issn | 2590-1230 |
| language | English |
| publishDate | 2025-09-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Results in Engineering |
| spelling | doaj-art-03cbecdcb388433db0b2dd27ee209edc2025-08-20T03:32:00ZengElsevierResults in Engineering2590-12302025-09-012710651810.1016/j.rineng.2025.106518Methodical approach to fixture design in the milling of thin-walled mechanical componentsNguyen Thi Anh0Tran Thanh Tung1Faculty of Engineering Mechanics and Automation, VNU University of Engineering and Technology, Hanoi, Vietnam; Faculty of Mechanical Engineering, Thuyloi University, Hanoi, VietnamFaculty of Engineering Mechanics and Automation, VNU University of Engineering and Technology, Hanoi, Vietnam; Corresponding author.The milling of thin-walled mechanical components presents unique challenges due to their low structural stiffness and high susceptibility to elastic deformation under machining and clamping forces. This study proposes a methodical approach to the design and validation of a specialized fixture system tailored for such thin-walled geometries, with a focus on motorcycle gearbox housings. These components often feature complex contours, irregular wall thicknesses, and functional surfaces that demand high dimensional precision. To address these requirements, the proposed fixture incorporates profile-matching jaws and pneumatic clamping to ensure uniform load distribution, reduce deflection, and prevent localized stress on delicate wall sections. The fixture design was evaluated through finite element analysis (FEA) to assess stress distribution and displacement behavior under operational loads. Experimental validation confirmed that the fixture maintained positional accuracy, suppressed vibration, and achieved consistent machining quality. The results demonstrate the effectiveness of the proposed fixture system in improving repeatability, surface finish, and structural integrity during the milling of thin-walled components, offering a viable solution for high precision, high volume production.http://www.sciencedirect.com/science/article/pii/S2590123025025873Fixture designCNC millingThin-walled componentGearbox HousingClamping system |
| spellingShingle | Nguyen Thi Anh Tran Thanh Tung Methodical approach to fixture design in the milling of thin-walled mechanical components Results in Engineering Fixture design CNC milling Thin-walled component Gearbox Housing Clamping system |
| title | Methodical approach to fixture design in the milling of thin-walled mechanical components |
| title_full | Methodical approach to fixture design in the milling of thin-walled mechanical components |
| title_fullStr | Methodical approach to fixture design in the milling of thin-walled mechanical components |
| title_full_unstemmed | Methodical approach to fixture design in the milling of thin-walled mechanical components |
| title_short | Methodical approach to fixture design in the milling of thin-walled mechanical components |
| title_sort | methodical approach to fixture design in the milling of thin walled mechanical components |
| topic | Fixture design CNC milling Thin-walled component Gearbox Housing Clamping system |
| url | http://www.sciencedirect.com/science/article/pii/S2590123025025873 |
| work_keys_str_mv | AT nguyenthianh methodicalapproachtofixturedesigninthemillingofthinwalledmechanicalcomponents AT tranthanhtung methodicalapproachtofixturedesigninthemillingofthinwalledmechanicalcomponents |