Preface	6
	Acknowledgements	8
	Contents	9
	Abbreviations	14
	Introduction	16
	Methodology	18
	Vibration	30
	1 Case Study 1.1: Identification and Active Damping of Critical Workpiece Vibrations in Milling of Thin Walled Workpieces	31
	Abstract	31
	1.1 Introduction of the Case Study	32
	1.2 Stability of Impeller Blade Machining Operations	34
	1.3 Single Degree of Freedom Test Rig	37
	1.4 Simulation of the Influence of a Counter Excitation	39
	1.5 Preliminary Prototype of Rotational Intelligent Chuck	41
	1.6 Sensor Integrated CFRP Structures	43
	1.7 Experimental Results	46
	1.8 Summary and Conclusion	50
	References	50
	2 Case Study 1.2: Turning of Low Pressure Turbine Casing	52
	Abstract	52
	2.1 Introduction of the Case Study	53
	2.2 Analysis of the Fixture and Workpiece	54
	2.3 Fixture Development	56
	2.4 Verification and Validation Tests	60
	2.4.1 Verification tests	60
	2.4.2 Validation tests	63
	2.5 Summary and Conclusion	64
	References	65
	3 Case Study 1.3: Auto-adaptive Vibrations and Instabilities Suppression in General Milling Operations	66
	Abstract	66
	3.1 Introduction of the Case Study	67
	3.2 Active Fixture Development	68
	3.2.1 Fixture Architecture and Mechanical Design	68
	3.2.2 Actuators Selection and Implementation	70
	3.3 Control Logic Development/Implementation	72
	3.3.1 Frequency Analysis and Excitation	73
	3.3.2 ANN Model and Simulation	74
	3.3.3 GA Controller	74
	3.3.4 Synthesis	76
	3.4 Validation Results	76
	3.4.1 Equipment and Test-Case	76
	3.4.2 Tests Description and Performance Assessment	77
	3.4.3 Results	78
	3.5 Summary and Conclusion	80
	References	81
	Deformation	83
	4 Case Study 2.1: Detection and Compensation of Workpiece Distortions During Machining of Slender and Thin-Walled Aerospace Parts	84
	Abstract	84
	4.1 Introduction of the Case Study	85
	4.2 Principle Approach	86
	4.3 Fixture Frame Test Rigs	87
	4.4 Sensor and Actuator Integration Concept	92
	4.5 Adaption of NC-Milling Paths	95
	4.6 Prototype of the Intelligent Fixture	97
	4.7 Process-Simulation Integrated Machining Operations	99
	4.8 Process Simulation of the Final Prototype	100
	4.9 Summary and Conclusion	102
	References	103
	5 Case Study 2.2: Clamping of Thin-Walled Curved Workpieces	105
	Abstract	105
	5.1 Introduction of the Case Study	106
	5.2 Demonstration Workpiece	107
	5.3 Introduction of the Fixture Unit	109
	5.4 Thickness Sensor	113
	5.5 Operator Software	114
	5.6 Communication Concept and Complete Fixture System Description	114
	5.7 Tool Selection and Cutting Condition Optimization	115
	5.8 Overall Machining Strategy	118
	5.9 Case Study Results	120
	5.10 Case Study Summary	121
	5.11 Conclusions	122
	References	122
	6 Case Study 2.3: Distortions in Aeronautical Structural Parts	123
	Abstract	123
	6.1 Introduction of the Case Study	124
	6.2 First Fixture Design	126
	6.2.1 Conceptual Requirements for Fixture 1	126
	6.2.2 Requirement Realization for Fixture 1	127
	6.3 Second Fixture Design	132
	6.3.1 Conceptual Requirements for Fixture 2	132
	6.3.2 Requirement Realization for Fixture 2	132
	6.4 Results	133
	6.4.1 Evaluation of the Stock Residual Stress Characterization and Part Distortion Modules	133
	6.4.2 Application of the Developed Methodology to the Test Part	135
	6.5 Summary and Conclusion	137
	References	138
	7 Case Study 2.4: Machining of Aircraft Turbine Support Structures	140
	Abstract	140
	7.1 Introduction of the Case Study	141
	7.2 Fixture Development	143
	7.3 Verification and Validation Tests	148
	7.3.1 Verification tests	148
	7.3.2 Validation tests	150
	7.4 Summary and Conclusion	154
	Positioning	156
	8 Case Study 3.1: Fixture System for Workpiece Adjustment and Clamping with/without its Pre-deformation	157
	Abstract	157
	8.1 Introduction of the Case Study	158
	8.2 Developed Solution Overview	159
	8.3 Fixture Design	161
	8.3.1 Static Fixture—Leveling Unit	161
	8.3.2 Static Fixture—Clamping Unit	162
	8.3.3 Dynamic Fixture	163
	8.3.4 Static Fixture for Clamping with Pre-deformation	164
	8.4 System Integration	165
	8.5 Validation under Real Conditions	168
	8.6 Summary and Conclusion	171
	Reference	171
	9 Case Study 3.2: Semiautomatic Tool Reference for Application on Large Parts	172
	Abstract	172
	9.1 Introduction of the Case Study	173
	9.2 Photogrammetry System	176
	9.2.1 Software for Minimisation of Material to be Removed	177
	9.2.2 On-machine Photogrammetric Process for Measurement of the Misalignment between the Part and the Machine Axes	177
	9.3 3-DoF Alignment Table Design and Fabrication	179
	9.4 3-DoF Alignment Table Control	182
	9.5 Verification and Validation	182
	9.6 Summary and Conclusion	185
	References	186
	10 Case Study 3.3: Active Fixtures for High Precision Positioning of Large Parts for the Windmill Sector	187
	Abstract	187
	10.1 Introduction of the Case Study	188
	10.2 Clamping Technologies	188
	10.3 General Overview of Requirements for Active Fixture Design Approach	189
	10.4 Detailed Description of the Proposed Fixturing Solution	191
	10.4.1 Clamping Technology	191
	10.4.2 Designed Lateral Linear Feed-Drive	192
	10.4.3 Design of the Fixturing	193
	10.4.4 Control of the Centering Process	194
	10.4.5 Intelligent Fixturing	195
	10.5 Experimental Validation	197
	10.6 Conclusions	199
	References	200
	Summary and Conclusions	201
	Author Index	203