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.

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PART DRAWING OF ONE SIDE OF THE CASE

Complete gearbox assembly

Bottom and Top views in AutoCAD.

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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

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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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