Gearbox Manufacturing Solutions
Gearbox Manufacturing Process
Raw Materials And Incoming Materials Inspection
- Verify alloy grade, dimensions, surface defects and heat‑treat state; sample chemical composition and hardness for the first lot.
- Optical spectrometer, universal testing machine, metallographic microscope, CMM, ultrasonic flaw detector, hardness tester.
Benchmarking And Roughing
- Establish datums and locating holes by turning/milling/drilling/boring and complete basic outer/inner features on housings and shafts.
- CNC lathe, drilling machine, milling machine, machining center,
Grinding Machine,mill‑turn center.
Gear Blank Soft Cutting
- Form basic tooth geometry by hobbing/shaping/milling prior to heat treatment to ensure stock allowance and accuracy.
- Gear hobbing machine, gear shaping machine, gear milling machine, gear machining center, tool grinder.
Shape And Feature Formation
- Performs spline/keyway broaching, soft cutting of tooth blanks, hole system finishing and on-machine probe compensation.
- Broaching machines, milling machines, drilling machines, on-machine measuring heads, compensation systems.
Heat Treatment
- Carburizing/quenching/tempering or induction hardening and stress relieving after tempering.
- Carburizing furnace, quenching furnace, tempering furnace, induction hardener, stress relief furnace.
Precision Straightening (Shafts)
- Remove distortion on heat‑treated shafts by multi‑point straightening and verify straightness online.
- High‑precision straightening machine, laser distance gauge, multi‑point straightening fixture.
Hard Tooth Surface Grinding
- Grind hardened gears with profile and lead modification to meet accuracy and NVH targets.
- Gear grinding machine, profile modification system, lead crowning system, gear measuring center.
Finishing And Surface Treatment
- Finish OD/ID/face by precision grinding and, where required, thread grinding and localized surface strengthening.
- OD grinder, ID grinder, surface grinder, thread grinder, laser hardening machine, roller burnishing machine.
Deburring And Cleaning
- Remove burrs by robot/high‑pressure/electrochemical deburring and achieve cleanliness via multi‑stage ultrasonic wash and drying.
- Robot deburring cell, high‑pressure deburring unit, electrochemical deburring unit, ultrasonic washer, vacuum dryer, cleanliness tester.
Assembly And Testing
- Assemble gearbox, set bearing preload/backlash, then run gear mesh, noise, and leak tests for 100% units.
- Assembly line/fixtures, gear meshing test bench, noise/vibration tester, leak test bench, torque/drag tester.
Final Inspection and Packaging
- Perform CMM inspection and visual check, laser mark ID/traceability, and apply anti‑rust packing for shipment.
- CMM, laser marking machine, barcode printer/scanner, vacuum/VCI packaging system.
Data Traceability And Quality Control
- Record process/inspection/assembly data via MES and SPC for full traceability and rapid containment.
- MES, data acquisition system, SPC software, QMS with barcode/RFID.
