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Machining fixtures are used to locate and constrain a workpiece during a machining operation. To ensure that the workpiece is manufactured according to specified dimensions and tolerances, it must be appropriately located and clamped. Minimizing workpiece and fixture tooling deflections due to clamping and cutting forces in machining is critical to the machining accuracy. An ideal fixture design maximizes locating accuracy and workpiece stability, while minimizing displacements. The purpose of this research is to develop a method for modeling workpiece boundary conditions and applied loads during a machining process, analyze modular fixture tool contact area deformation and optimize support locations, using finite element analysis (FEA). The workpiece boundary conditions are defined by locators and clamps. The locators are placed in a 3-2-1 fixture configuration, constraining all degrees of freedom of the workpiece and are modeled using linear spring-gap elements.

The absence of a design and manufacturing template that can be used to develop a product is the basis for this paper. A machine grouping algorithm based on machine utilization factors is discussed. The algorithm was developed based on traditional machine grouping models, but has been modified to use the machine utilization factors to group machines into cells. Different floor layouts for a factory are considered and an optimal floor layout is determined. The WPI World Formula SAE manufacturing facility is used as a model to demonstrate the algorithm. The FSAE competition required the design of an optimal factory layout manufacturing 1000 cars/year. Total costs and times of manufacture for each sub-component of the WPI FSAE racecar are determined. These total times and costs are used to develop the machine and labor requirements for a fictitious company producing 1000 racecars/year. The proposed algorithm is used to group machines into cells on the factory floor.