GEARBOX CASE Roll no : 07010042 Name : Jyoti Swaroop • Material : 6061 – T6 Aluminum • Processes : • Lost foam aluminum casting • CNC machining • Dimension inspection. • Material testing (NDT). • Quality assurance and after-sales service. 1
Apr 27, 2015
GEARBOX CASE
Roll no : 07010042Name : Jyoti Swaroop
• Material : 6061 – T6 Aluminum
• Processes : • Lost foam aluminum
casting• CNC machining• Dimension inspection.• Material testing (NDT).• Quality assurance and
after-sales service.
1
PART DRAWING OF ONE SIDE OF THE CASE
Complete gearbox assembly
Bottom and Top views in AutoCAD.
2
MATERIAL – 6061 T6 ALUMINUM
A precipitation hardening aluminum alloy.
Reasons for choice: Good mechanical properties
High strength to weight ratios. (tensile strength = 290 MPa, density = 2.70 g/cm3)
Low density.
Workability High weldability Easy to drill and machine.
Excellent at resisting moisture.
Characteristics Composition
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PROCESS EQUIPMENT AND TOOL DESIGN-1LOST FOAM CASTING
Procedure followed :
1. Foam gearbox is built from the required design. (draft=0.6°)
2. 0.95cm thick layer of sand has to be formed.
3. The foam is removed using acetone.
4. Casting heated for 2hrs at 900°C in a furnace.
5. Metal heated in Intermediate frequency furnace is poured. (@ 647°C)
Tool design Foam pattern
4
Sand casting ready
PROCESS EQUIPMENT AND TOOL DESIGN-2MACHINING AND FINISH PROCESSES
CNC machining :• computer numerical
controlled machining.• used to machine complex
parts.• Capable of holding tight
tolerances.• end-to-end design is highly
automated using CAD/CAM.
o Surface finish processes :o Polishingo Shot blasting –
o to remove something on the surface
o large air gun or spinning paddles throw the shots.
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QUALITY ASSURANCE PLAN QA steps- 1.failure testing, 2.statistical
control (6σ), 3.Total quality control (RMSS) and 4.Quality awareness.
Dimension testing : Either manually – cheaper. Or using a reliable Coordinate Measuring Machine
(CMM). – accuracy, expensive.
Non-Destructive testing using UT-machine. Competitive advantages :
Experience technical staff-productivity. Product features testing – NDT. Product performance – stress analysis
(SADSAM)and factor of safety. Prompt delivery. Quality approvals. After sales service – optimal warranty period.
Dimension testing
NDT
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