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| Gearbox |
| Aluminium Gearbox casting |
| This project was to fixture an industrial gear box casting, preferably on a fourth axis trunnion plate, unfortunately the machine HAAS VF3 did not have the height to swing the gearbox. We then were able to start with a clean sheet and the approach we took was to manufacture an angle plate big enough to take the gearbox. The gearbox was clamped to a fixture plate which in turn was located and clamped to the angle plate. With the box needing machining on three of the four sides we decided to use 'Jergens' Ball Lock locations and locate on the two inside faces of the angle plate. This meant we were able to clamp the gearbox to the fixture plate once and move the fixture plate three times, thus minimising the margin of error incurred when unclamping/re-clamping the gearbox. |
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| The first operation involves in line boring 2 lots of 5 progressive diameters with two special tools. Circlip grooves to be machined on each bearing diameter. Face mill top faces. |
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| The second operation involves turning the gearbox through 180 degrees so that the machined face now points to the bed. The face now presented can be drilled & tapped for the cover plates. Circlip grooves can be machined on last bores. |
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| In the last operation the gearbox is revolved throgh 90 degrees so that the machined faces are running front to back ('Y') axis. The top face can then be face milled, drilled and tapped for a cover plate. |
| A special lifting beam was made to facilitate loading and turning the fixture plate to the angle plate. |
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© Brew-Eng last modified 16/02/2000 |
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