Fan Hub

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Aerostar Manufacturing, based in Romulus, MI, continues to showcase its commitment to precision and quality in every project. Recently, we undertook the production of Fan Hubs. These hubs are essential components in various mechanical applications, requiring precise engineering and rigorous quality control throughout the entire manufacturing process.

Aerostar Manufacturing, based in Romulus, MI, continues to showcase its commitment to precision and quality in every project. Recently, we undertook the production of Fan Hubs. These hubs are essential components in various mechanical applications, requiring precise engineering and rigorous quality control throughout the entire manufacturing process.

From the moment the raw materials arrive, our Receive Inspection ensures that every part meets strict standards. During this stage, materials undergo a thorough visual inspection to confirm they are the correct product and free from damage, contamination, or rust. Once approved, the materials are securely stored before moving into the next stage of production.

The machining process for the Fan Hub primarily involves lathe operations, where critical dimensions such as diameters, milled faces, and chamfered edges are meticulously machined. Throughout this phase, attribute gages, variable gages, and Coordinate Measuring Machines (CMM) are employed to monitor and verify all dimensional specifications. Each key feature—such as surface finishes, mounting holes, and grooves—is subjected to stringent inspection to ensure compliance with design requirements.

Quality is paramount at every step of the manufacturing lifecycle. Our inspection process integrates calipers, micrometers, and go/no-go plug gages to ensure every dimension and feature meets exacting standards. Any deviations trigger immediate corrective actions to maintain the integrity of the production process.

Finally, at the GP12 Inspection / Pack stage, each Fan Hub undergoes a final visual inspection for surface defects and correct identification. Parts that meet the stringent criteria are carefully packaged and prepared for shipment, with final oversight by both our Quality and Engineering Managers to guarantee the highest level of quality.

This project exemplifies Aerostar Manufacturing’s dedication to producing high-quality, reliable components through a meticulous, multi-step process designed to ensure superior performance in every product we deliver.

Project Overview

Quality, Inspection, and Measurement Steps

  • Receive Inspection: Visually inspect materials for correct product type, damage, and contamination (e.g., rust).
  • Dimensional Inspection: Verify part dimensions using gauges (attribute, variable, or CMM) for precise measurements.
  • Surface Finish Inspection: Visually check for any surface defects or irregularities.
  • Hole Location and Diameter Check: Measure hole diameters and locations with appropriate plug gauges and calipers.
  • Chamfer and Radius Inspection: Confirm chamfer angles, depth, and radius conformity using scales or calipers.

Equipment and Tools Used for Quality and Inspection Tools

  • Calipers: For dimensional measurements of diameters, depths, and chamfers.
  • Plug Gauges (Go/No-Go): To inspect hole diameters.
  • Micrometers: For precision depth and surface measurements.
  • CMM (Coordinate Measuring Machine): To inspect part locations and alignment.
  • Visual Inspection Tools: Magnifiers, lights, and mirrors for surface defect detection.

These steps often intertwine with manufacturing steps to ensure a feedback loop exists between the production process and quality controls. Discrepancies detected during quality checks can lead to modifications in the manufacturing steps.

Manufacturing Steps

  • Material Preparation: Receive and store raw materials for machining.
  • Machining Operations: Perform turning, milling, and drilling on lathe and other machine tools to achieve required dimensions.
  • Hole Drilling and Chamfering: Machine necessary mounting holes and apply chamfering as per design requirements.
  • Surface Finishing: Apply grinding and other finishing processes to achieve smooth surfaces and specified tolerances.
  • Final Assembly and Packaging: After machining and inspections, assemble parts and prepare them for shipping.

Equipment and Tools Used for Manufacturing Steps

  • Lathe Machine: For turning and shaping parts to required dimensions.
  • Milling Machine: For creating flat surfaces and precise hole locations.
  • Drill Press: For accurate drilling of holes.
  • Grinder: To achieve smooth and precise finishes on surfaces.
  • Fixture Setups: For securing parts during machining and ensuring stability.

The steps in manufacturing are often revisited based on the results of the quality checks. For example, if an intermediate inspection detects an issue, the material may go back to the assembly stage.

Manufactured Components and Parts

  • Machined Fan Hubs
  • Castings for Machining
  • Bore Holes and Mounting Holes
  • Flanges and Surface Grooves
  • Chamfered Edges and Radii