This master’s thesis investigates the development of a new approach to joining the rotor of an electric motor, based on local deformation of the core laminations at the interface with the shaft. We addressed the shortcomings of conventional solutions, such as complex machining requirements, higher production costs, and limited repeatability in serial manufacturing. We developed a concept that enables reliable transmission of torque and axial forces without additional shaft processing. Using finite element method simulations, we analysed the distribution of contact pressure and the strain state of the joint. Based on the simulation results, we produced prototypes and tested them experimentally under real operating conditions. The results confirmed the mechanical reliability of the developed joint, consistent process repeatability, and its suitability for integration into industrial environments. We concluded that the proposed solution represents a technically and economically competitive alternative to established rotor joining methods and offers potential for further optimization of electric motor design and manufacturing.
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