Abstract—The machining of irregular and thin-walled components presents significant challenges due to their complex geometries, low stiffness, and high susceptibility to deformation under clamping and cutting forces. Conventional rigid vises and specialized fixtures often fail to provide stable and adaptable workholding without costly redesigns. This study aims to develop and validate a modular flexible clamping fixture that combines segmented jaws with a standard machine vise to enhance adaptability, stability, and machining precision. The fixture was designed using a modular assembly of aluminum jaw segments capable of self-adjusting to complex contours. Finite Element Analysis (FEA) was conducted to evaluate stress distribution and displacement under clamping loads, ensuring structural integrity and sufficient stiffness. A prototype was fabricated and experimentally tested through clamping trials on irregular and thin-walled workpieces, as well as milling experiments on asymmetric aluminum parts. Quantitative displacement measurements using a dial indicator confirmed repeatable clamping with an average displacement of 0.12 mm (±0.02 mm). Results demonstrated that the fixture provided uniform force distribution, minimized risk of slippage, and maintained part integrity under machining conditions. Compared with conventional rigid vises, the proposed design offered greater adaptability and improved repeatability while remaining simple and cost-effective. These findings highlight the fixture's potential for practical industrial use and its extendibility toward automated and intelligent.

Keywords—irregular workpieces, thin-walled workpieces, flexible clamping, fixture

Cite: Nguyen Thi Anh and Tran Thanh Tung, "Development of Flexible Clamping Devices for Precision Workholding of Irregular and Thin-Walled Workpieces," International Journal of Mechanical Engineering and Robotics Research, Vol. 14, No. 6, pp. 676-684, 2025. doi: 10.18178/ijmerr.14.6.676-684

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