2. By Dean Mckinstry National Diploma Project Electro Plating Fixture

3. Design Brief I am going to produce a fixture for electro plating increasing productivity at T.J plating's production for one product line

4. Process Electroplating is the process of plating one metal onto another, most commonly for decorative purposes or to prevent corrosion of a metal.

5. Major Design Parameters Increase productivity Fisher engineering parts Mass is 1.1kg 25mm clearance between parts Set up by one person Offers flexibility

6. Major Customer Requirements The costumers main demand is the quantity per dip, which means he is wanting a fixture that will support more work and he also wants a quicker set up time. The main purpose of his demand is to boost production.

7. Product Design Specification When I was at the factory I was able to get lots of information such as: The type of acid that is used for plating is hydrochloric acid The bath is 400mm wide and the rail used to hold the jig is 2400mm long. The product I will be working with is 45mm box section and 1080mm long and the spacing between hooks will have to be 80mm apart for a high quality plating job. The motor used for the crane is 5hp. The maximum load the crane can withstand is 1000kg

8. Testing I have come up with a testing frame which will allow me to test different fixtures out to see which design could work the best

9. Concepts The limitation is, this will be difficult to set up because its hanging, fixture would need to be balanced on the frame This design is balanced but it doesn’t have any fixed positions, it possibly hasn’t got enough circulation This is the best solution but I wanted to try and improve it to be easier to manufacture.

10. Concept selection Simple to make Welded frame Fits to existing hanger Uses no tools to secure High stress and high loading may mean its difficult to lift

11. Design development Modular i.e. 3 sections Make 1 section 750mm long sections Capacity of 54/3 Loading gantry is 54 x 1.1kg i.e. 59.4Kg, fully loaded Spacing of 80mm meaning 50mm circulation

12. Detailed Design Demand is 1500 parts plated per week Cost £2,50 per part per job Demand is 250 per working day 18 per batch, 3hour cycle time 16 hours per working day Old capacity – 14 x 18 units = 252 per day 1512 per week New capacity 14 x 54 units = 756 per day 5 day week = 3780 6 day week = 4536 Or no night shift i.e. 8am to 4pm 54 x 6 x 6 = 1944 parts plated on a 6 day week I.e. night shift wages reduced by 8 x 6 x £15=£720 per week

13. Productivity Output increased by 150% Saving over £35000 per year on labour 18 units at £2.00 = £36 46 units at £2.00 = £92 Profit increased by £56 per batch

14. At R1 F x D= M CM= ACM 2.4 R2= 103 x 0.075m + 206 x 0.825 + 206 x 1.575 + 103 x 2.325 = 7.725 + 169.95 + 324.45 + 239.475 2.4R1= 741.6 Nm R1= 309N

16. How my fixture was made: Measured out 4 pieces of 30x30mm angle iron, two were 750mm and the others were 300mm Cut a 45 degree angle at each corner Welded each corner together with a MIG welder Measured and cut holes with 80mm spacing Welded a mounting bracket to each end of the fixture