Question

6.1 Housing of gearbox

analyse and identify the manufacturing processes used to make the component – both primary (bulk shape forming) and secondary (or finishing) processes. Include sub-sub-section as follows for each component:
o 6.1.1 Component Observations
? Describe your observations of the physical component which indicate what manufacturing processes were performed.
o 6.1.2 Manufacturing Process
? With supporting literature and research, describe the chosen manufacturing process concisely in detail, noting its advantages and disadvantages – describe it in the context of the gearbox you are looking it, not just generally.
? Detail the advantages and disadvantages of these processes
? Relate the chosen method to production volume of the gearbox.
o 6.1.3 Material Relationship
? Relate to the material and its appropriateness in this manufacturing method (e.g. does it have suitable castability?)

Thank you.

Answer 1

6.11) Gear box housing must be vibration resistant and have enough strength. So previously cast cast iron housings were used. Now aluminium alloys are used. The other components inside a housing include gears, shafts and pins etc. Gears are manufactured from alloy steels by gear bobbing or gear shaping. Splinter are cut on it by broaching process. Gears are surface hardened to increase wear resistance.

6.12) Gear housing is made by casting. After casting it is machined fby milling and drilling for required surface finish. After milling the required surface finish is not achieved. Hence further grinding with a hard abrasive wheel is done for finishing.

6.13)Aluminium alloys for housing reduces weight and are easy to made by casting in bulk. Permanent die casting is used. Shafts made of alloy steel have enough fatigue life and are machined using coated tools. otherwise tool wear will be high and surface finish is reduced.