Facing challenges in a single setup clamping situation

Vioral SA is an aluminium high pressure die casting company with a strong automotive focus, operating with a clear emphasis on automation, process discipline, and international customer programs.

For a new high-runner electromobility component, Vioral faced a double challenge:

1. Single-setup, 4-axis machining in one operation
   The part had to be machined in one clamping operation, including machining against the clamping elements, while remaining stable under strong cutting forces.
2. Repeatable location despite casting fluctuations
   The cast part needed reliable, repeatable positioning even when deviations occurred due to the casting process, including drafted cast surfaces.

Vioral integrated KOSMEK components directly into the fixture design to solve both requirements:

1. Clamping for machining against the lever
   Vioral selected the High-Power Pneumatic Swing Clamp (WHE) series to achieve strong holding forces combined with a locking mechanism that enables machining against the lever while minimizing the impact on machining stability (including chatter sensitivity). Learn more about High-Power Technology.
2. Accurate location tolerant to casting deviations
   To secure repeatable positioning, Vioral implemented the Pneumatic Expansion Locating Pin (VWK) expansion locating pin. Its expansion principle supports high repeatability even on drafted cast surfaces, while the clearance between the retracted and expanded states helps absorb casting deviations without compromising clamping quality.