Development of a Clamping Fixture for Portal Axle Metallisation

In the diploma thesis entitled Development of a Clamping Fixture for Portal Axle Metallisation, the focus was on the design and optimisation of a clamping fixture that improves the metallisation process at BVT Beschichtungs- und Verschleißtechnik GmbH. The main objective of the research was to develop a fixture that enables precise, repeatable and ergonomic clamping of workpieces. Such a fixture is crucial for the successful execution of metallisation processes, which require a high degree of precision and reliability. The test results showed that the new clamping fixture meets the assumptions regarding clamping precision and repeatability. The fixture enabled stable and efficient metallisation with minimal vibrations, which is very important for achieving uniform and high-quality surface treatment.

Problem

In the diploma thesis entitled Development of a Clamping Fixture for Portal Axle Metallisation, the focus was on the design and optimisation of a clamping fixture that improves the metallisation process at BVT Beschichtungs- und Verschleißtechnik GmbH. The main objective of the research was to develop a fixture that enables precise, repeatable and ergonomic clamping of workpieces.

Solution and Method

Such a fixture is crucial for the successful execution of metallisation processes, which require a high degree of precision and reliability. In the first part of the diploma thesis, an analysis of existing clamping methods was carried out and their advantages and disadvantages were evaluated. This analysis served as the basis for formulating research questions and hypotheses about potential possibilities for improving the clamping process.

The focus was on challenges related to the precision, stability and adaptability of the clamping fixture, which led to the development of a concept that meets all the mentioned requirements. Modern CAD tools were used to design the clamping fixture, with which comprehensive technical documentation was prepared. The development process also included the use of CAM technologies for the preparation of manufacturing processes.

The individual stages of prototype production were described in detail, including sawing, turning, welding and milling. After the prototype was manufactured, the fixture was tested under real production conditions.

Results

The test results showed that the new clamping fixture meets the assumptions regarding clamping precision and repeatability. The fixture enabled stable and efficient metallisation with minimal vibrations, which is very important for achieving uniform and high-quality surface treatment. The main advantages include cost reduction, shortened workpiece preparation time and increased fixture durability.

Based on the findings, recommendations for further improvements to the fixture were prepared. Possibilities for automating certain processes were proposed, which could further increase productivity and precision. The need for further research in the field of materials and design solutions was also highlighted, which could improve the fixture's resistance to wear and its adaptability for various industrial applications.

This diploma thesis represents a contribution to the development of advanced clamping fixtures that improve production processes in the metallisation industry. The research results are directly applicable in practice and have the potential for wider use in industrial sectors where high precision and efficiency are required. The thesis also offers broader starting points for further research and development in the field of mechanical engineering.