Fixture Layout Optimization of Sheet Metals by Integrating Topology Optimization into Genetic Algorithm

Manufacturing process accuracy is obtained by proper arrangement of fixture elements known as fixture layout. A N-3-2-1 method is used for sheet metals which requires (N + 3) fixture elements to constrain deformation normal to surface. Genetic Algorithm (GA) is used for fixture layout optimization, but it requires high computational effort due to large number of populations. A new method for fixture layout optimization is proposed by integrating topology optimization into GA. In this method, topology optimization reduces the population for GA. The objective function is to reduce the population for GA and minimize total deformation normal to the plane of workpiece. The proposed approach comprised three stages. In the first stage, the initial number of clamps are determined. In the second stage, the population is reduced for GA and the feasible area of clamps are identified using the topology optimization technique. In the third stage, the number and position of clamps, earlier identified in stage one, are optimized using GA. Two different case studies are solved by varying applied load position and magnitude. The proposed method results 47.5% and 65% decreases in the population for subcase 1 and subcase 2, respectively. However, in subcase 3 and subcase 4 the population reduced was 90% and 80%, respectively. The 25% of reduced population is used as the convergence criteria. Similarly, total deformation normal to the plane is reduced in each subcase, with the highest reduction of 86.31% in subcase 1 and lowest of 59.85% in subcase 4. The experiment is performed on the first case study to validate results. This concludes that the proposed method is valid and that optimal results are found.