GEARBOX CASE

Roll no : 07010042
Name : Jyoti Swaroop

• Material : 6061 – T6 Aluminum

• Processes :
• Lost foam aluminum casting
• CNC machining
1 • Dimension inspection.
• Material testing (NDT).
• Quality assurance and after-sales
service.
PART DRAWING OF ONE SIDE OF THE
CASE
Complete gearbox assembly Bottom and Top views in AutoCAD.

2
MATERIAL – 6061 T6 ALUMINUM
Characteristics Composition

 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.

3
PROCESS EQUIPMENT AND TOOL
DESIGN-1
LOST 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.
Foam pattern 4. Casting heated for 2hrs at 900°C
Tool design
in a furnace.
5. Metal heated in Intermediate
frequency furnace is poured. (@
647°C)

Sand casting ready

PROCESS EQUIPMENT AND TOOL
DESIGN-2
MACHINING 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 Polishing
o Shot blasting –
o to remove something on the

surface
o large air gun or spinning

paddles throw the shots.

5
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.
Dimension testing
 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.
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 After sales service – optimal warranty period.
NDT