Аннотация
This article discusses the current scientific and technical challenge of improving the efficiency of processing complex spatial shapes of body and thin-walled parts in small-batch production. Traditional tooling often does not provide the required rigidity and flexibility, which leads to vibrations and deformations of workpieces. The authors propose an innovative design for adaptive tooling, a distinctive feature of which is the use of a polymer concrete base and a matrix of telescopic pins positioned by stepper motors. The main focus of the work is on evaluating the strength and load-bearing capacity of the new design using the finite element method (FEM) in the Ansys Discovery 2024 R2 software package. During simulation modeling, the behavior of the system under the influence of a significant static load of 100,000 N was investigated. S275N steel was used for the pins and epoxy-based polymer concrete for the frame. The analysis results showed high rigidity of the system. The maximum displacements were only 4.53 μm and were localized at the tops of the pins, without exceeding the elastic deformation zone. The study of equivalent stresses according to Mises confirmed that the peak values (4.58 MPa) are many times lower than the yield strength of steel (237 MPa). The use of polymer concrete is justified by its ability to effectively dampen vibrations and ensure geometric stability at low levels of internal stresses. It has been established that the critical value of the coefficient (n > 1.5) is reached at loads exceeding 550–600 kN, which is equivalent to a workpiece weight of more than 56 tons. Thus, the developed tooling is a promising solution for precision machining of heavy and complex parts, combining adaptability, vibration resistance, and high load-bearing capacity