Optimized Design of Flexible Quick-Change System Based on Genetic Algorithm and Monte Carlo Method

Abstract

In order to realize the high efficiency and precision clamping of large workpieces with several processes and multiple species processing, the distribution number and position of the zero point clamping unit in the flexible quick-change process system for big thin-walled cylindrical structural parts are presented. The error model of the flexible quick-change process system is established by the Monte Carlo method, which is used to optimize the system structure design. The error variation of the flexible quick-change process system under the action of transposition and extreme working conditions such as cutting force is revealed, and further analysis on the sensitivity of the workpiece’s global displacement error and global attitude error to each error source is carried out. After the optimization, a high-quality, cost-effective, flexible quick-change clamping system is created. The three-coordinate measurement experiment is used to test the functionality and accuracy of the flexible quick-change process system. A significantly improved level of the system’s repetitive positioning accuracy (less than 0.01 mm) is detected. Importantly, the flexible quick-change system obtained by the combinatorial optimal design method has been successfully applied to the production of aerospace components with improved quality and efficiency.