Design of a Test Rig for a Novel Joining Method

This paper presents the development of an experimental setup in order to study a novel assembly method based on knurling. The assembly method is used as an alternative to the ordinary lathing process. The idea arises from the necessity of finding a new method of manufacturing work-pieces which would not generate turnings during the process, as well as having the possibility of hollowing the work-piece in order to reduce its weight and save costs. The resultant design is a combination of electro-mechanical tensile test machinery, available in the market and a designed part. The test rig is composed by the machinery, which performs the principal functions of movement and force and two clamping devices for fixing the two work-pieces during the assembly. The clamping is designed to allow fixing different sizes and shapes of the work-piece as well as to let the clamp orientate the work-piece. By gathering information through a market research and literature review, different design methodologies are applied in order to find the most suitable design. Thereafter, the final design is modelled and simulated in Pro/Engineer Wildfire 5.0 in order to analyse its most critical zones and to enhance the reliability of the design. It is concluded that the design fulfils the requirements established and contributes to the development of the novel assembly method. However, some parts may be refined, and as future work, the test rig could be prototyped and tested as well as implemented in the Company