transfer tool has the zero-point pallet and grippers. Te grip- pers are placed where needed to support the workpiece during machining. Transfer tools do not need to be accurate or built to maintain accuracy between tools since the actual locators are in the bond station, not the transfer tool. Te grippers are load-bearing light guides built to take the
abuse of an industrial enviroment in which the workpiece is adhered to through the use of an eviromentally safe propri- etary photo-curable UV workholding adhesive and a high- intensity UV light source. Te grippers are positioned on one side of the workpiece providing five-sided and in some cases six-sided machining access.
Automation of Complex Part Shapes Te Blue Photon system simplifies automation for even the
most complex part shapes. Once the workpiece is bonded it can be loaded into several subsequent machines using a stan- dard off-the-shelf zero-point system that allows the workpiece to be loaded with a robot in seconds, while realizing load repeatability of ± 2 µm. Te bond station can be built to ac- commodate multiple part configurations within the same bond station. With this system the only changes made to the produc- tion system are in the machine control with a program change. With regards to complex workpiece shapes, manufactur-
ers are likely to have several expensive and custom one-off fixtures on the shelf. Te Blue Photon system allows manu- facturers to standardize machine tooling through the use of a zero-point system. All machines and bond stations in the production line are fitted with a zero-point chuck. All transfer tools regardless of the workpiece configuration have the same zero-point pallet installed. Tis method of manufacturing decreases setup time, increases output and profitability while simplifying and standardizing workholding throughout the production lines.
Workholding Technology Attributes Te BlueGrip Adhesives are the first UV-curable adhesives
specifcally formulated for workholding. Te BlueGrip C1 is an adhesive designed for bonding ceramics, ferrous or nonfer- rous materials to the gripper. It is used when there is a chance of delamination or when high holding strengths are not re- quired. Te BlueGrip S1 was formulated where high machin- ing loads are seen. Te BlueGrip adhesives in both the cured and uncured state are nontoxic. Te adhesives can be applied manually using a 30-ml syringe or with a fully automated dispensing system. Since overhead clamps are not needed, more freedom is
available to stiffen a workpiece using adhesive joints in com- parision to conventional mechanical supports. Adhesive joints are very strong and capable of withstanding large, dynamic forces. Adhesive joints are stiff, viscoelastic, and capable of dissipating vibrational energy in the workpiece. Uncured ad-
Complex parts can be easily fixtured and loaded into machines via automation.
hesive naturally conforms to irregularities in the geometry of the workpiece surface and fills the gap between the workpiece and the gripper. Te universal workholding fixture allows users great
flexibilty. Grippers can be placed where needed to accommo- date the part shape. Te fixture can be bolted directly to the machine bed or a zero-point system can be used to load the fixture for machining.
Side-by-Side Comparison SME’s Journal of Manufacturing Systems published a paper
entitled “Assessment of Photo-activated Adhesive Workholding (PAW) Technology for Holding ‘Hard-to-Hold’ Workpieces for Machining,” (August 2010) which compared a conventional fixture with Blue Photon’s technology and concluded that: “Te data reveals that the system cycle time for the Blue Photon System is 46% smaller than the existing PGM solution. Te difference is due to the reduction in average setup time [and] the elimination of the workpiece setup error checking proce- dure associated with conventional solution. ... Te Blue Photon System solution increases the percentage of system cycle time devoted to chip machining from 24 to 50%. Te engagement percentage of the operator is reduced from 76 to 43%.” ✈
Aerospace & Defense Manufacturing 2014 137
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