Study of the efficiency of additive manufacturing for clamping mechanisms in technological equipment

INTRODUCTION: This paper investigates the applicability of modern additive manufacturing (AM) technologies to the production of components for clamping and locating (workholding) devices used in mechanical engineering. Using a modular machine-tool fixture as a case study, the feasibility of replacing metallic parts with engineering polymers, including fiber reinforced grades, manufactured by AM is assessed. STUDY OBJECT: A two arm workpiece clamping lever was selected for analysis as the most highly loaded element of the fixture used for machining a “crosspiece” part. METHODS: Based on recommended cutting conditions, the cutting force components were determined, and the required clamping forces were calculated for several scenarios representing a potential reduction in holding capacity (clamping weakening). These loads served as input for strength and stiffness calculations. Equivalent stresses and deflections were evaluated for the baseline steel lever and for alternative designs made from the most common AM polymers. RESULTS: The study shows that polymer levers with the original geometry do not satisfy allowable stress limits and stiffness requirements. Therefore, the lever geometry was refined by modifying the cross section to achieve the required strength and rigidity under operating loads. Among the materials considered, the optimized lever made from PA6 GF30 provides material savings and lower manufacturing cost while maintaining adequate strength and deformation limits. CONCLUSIONS: The results confirm the feasibility of using fiber reinforced engineering plastics in additive manufacturing for producing components of clamping and locating fixtures. Further work is required to assess AM fabrication of other, less highly loaded parts and to quantify the influence of print induced anisotropy and process parameters on mechanical performance.