Adaptive Workpiece Support Plate for Rigid Low-Stress Machining
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Solution Overview
Problem
Existing tooling fixtures for machining operations are expensive and not economically viable for small production runs, and they often apply undesirable preload or stress on workpieces during adjustment due to their complexity in adapting to different geometries.
Innovation Solution
An adaptive workpiece support system comprising a wear plate with a precision datum face and a grid of tool holes extending through the wear plate, which interacts with accessories to support, locate, and hold a workpiece against the wear plate, allowing for adjustable positioning relative to three axes of a machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional tooling fixtures are used to rigidly support workpieces, then support rigidity is improved, but cost increases and economic viability decreases for small production runs
Solution Approach 1:
The fixture system is divided into modular components: a base plate with grid-pattern locating holes, adjustable support elements, and independent clamping mechanisms. This segmentation allows only the necessary components to be manufactured and assembled, reducing overall cost while maintaining rigidity through proper modular integration.
Solution Approach 2:
The base plate incorporates a universal grid pattern of locating holes that can accommodate various workpiece sizes and geometries. The same fixture system can be reconfigured for different production runs, eliminating the need for multiple specialized fixtures and reducing per-unit cost for small production volumes.
2Adaptability or versatility
If tooling fixtures are designed to adapt to different workpiece geometries, then versatility is improved, but device complexity increases and preload/stress control deteriorates
Solution Approach 1:
The fixture provides localized adaptation through individually adjustable support elements and selective use of locating holes in the grid pattern. Each support element can be independently positioned and adjusted to match specific workpiece geometry requirements without requiring the entire fixture to be complex or reconfigurable.
Solution Approach 2:
The fixture incorporates adjustable and movable components that allow dynamic reconfiguration for different workpieces. The grid pattern of locating holes enables flexible positioning, and supports can be adjusted to different heights and positions, providing adaptability without permanent complex mechanisms.
3Ease of operation
If adjustable supports are used to accommodate varying workpiece positions, then positioning flexibility is improved, but the risk of applying undesirable preload or stress increases
Solution Approach 1:
The fixture employs predetermined locating features in the grid pattern that establish accurate workpiece positioning before clamping or machining forces are applied. This preliminary location ensures proper alignment and distributes forces evenly, preventing undesirable preload or stress during subsequent adjustment and machining operations.
Solution Approach 2:
The grid pattern of locating holes acts as an intermediary system between the workpiece and the adjustable supports. This standardized interface allows precise positioning while decoupling the workpiece from direct contact with adjustment mechanisms, reducing the risk of stress concentration and undesirable preload during positioning adjustments.
Data Source
AI summary
An adaptive workpiece support system comprising a wear plate comprising a precision datum face and a plurality of tool holes, and accessories interactive with the plurality of tool holes of the wear plate to support, locate, and hold a workpiece against the wear plate for machining the workpiece. The plurality of tool holes is laid out in a grid and extending through the precision datum face, a thickness of the wear plate, and a backside face of the wear plate. The wear plate is configured to locate a workpiece relative to three axes of a machine.