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Assurance of accuracy for machining parts and their work’s reliability is achieved using fixtures with the required accuracy of the locating and the workpiece reliable fixing. The expansion of state-of-the-art metal-cutting equipment’s technological capabilities necessitates using advanced fixture designs to be fully utilized. It requires the application of new approaches and the necessity of advanced fixture design. Fixture design for complex parts machining can reduce the auxiliary time for setup remains especially relevant. A flexible fixture design that provides tool accessibility multiaxis machining of fork-type parts for one setup is proposed. Refusal of full locating, application of industrial robots, and two fixtures for parts machining allows combining auxiliary time with cutting time. The numerical simulation results confirmed that the fixture meets all the strength, accuracy, and stiffness parameters. It allows the application of intensive cutting modes, which will provide the greatest efficiency when using modern machine tools and cutting tools. Oscillation amplitudes in the work surface positions do not exceed these surfaces’ size tolerances.

The paper is dedicated to the increase of the efficiency of multiproduct manufacturing. The experience in designing the manufacturing processes of manufacturing machining parts, such as connecting rods, is analyzed. A progressive manufacturing process based on the concept of intensification of machining and application of multiaxis equipment is proposed. This approach made it possible to reduce the complexity of the manufacturing process in drilling, milling, and boring operations. Research has been conducted on the design, optimization, modeling, and production of fixtures for multiproduct manufacturing. The design of a flexible fixture for machining non-detachable connecting rods is provided, which allows adjustment of locating and clamping elements in a certain size range. Studies have shown an increase in machining productivity of the proposed manufacturing process from 1.7 to 3.9 times depends on batch size.

Fixtures play an important role in the production of high-quality and competitive products, especially in the context of multiproduct manufacturing, which requires fast reequipment in the transition to the machining of parts of the other type. The article deals with the problem of determining the optimal dimensions of the fixture functional elements for machining of the lever-type parts within a given size group. The purpose of the research is to increase the efficiency of machining by optimizing the design of a flexible fixture through the proper choice of parameters of the fixture elements. Fixture configurations were analyzed by means of the parametric optimization algorithm. The reserves for fixture optimization were revealed, and possible variants of the fixtures for the limiting size of the levers within the given size group were investigated. Based on the research of static structural, modal, and harmonic analyses of fixture configurations, optimal parameters of each element of the flexible fixture were found out. The optimal design of the fixture is proposed, which can provide multiaxis machining of all sizes of levers within a given size group with the required accuracy.

The ways of intensification of machining complex parts of vehicles on the modern metal-cutting equipment were described. The classification of parts such as levers was developed on the basis of design and technological features. Based on the developed classification the structural code that allows to encode any lever design was proposed. The structural code can be used in computer-aided fixture design and in information retrieval systems for selecting optimal fixture for levers. The reasonability of intensification of parts machining such as levers was substantiated, the typical manufacturing process was analyzed, and opportunities for optimization subject to current trends in machining and technological capabilities of modern equipment were identified. The adjustable locating-and-clamping module characterized by high level of flexibility was proposed for CNC multiaxis machining operation. Comparative analysis of manufacturing processes by labor content, quantity of fixtures and machine tools, number of setups, and production area was performed.