Aerostar Manufacturing successfully employed a rigorous and ISO-certified Gear Cover Brace machining process, starting from careful material procurement to delivering immaculate components to its clients. The process is integral to various applications such as gear assembly, machine tool development, engine component manufacturing, and power transmission systems and is relevant to diverse industries like automotive, aerospace, heavy machinery, marine, robotics and automation, agricultural machinery, and mining equipment.

Aerostar Manufacturing embarked on a meticulous Gear Cover Brace machining process that aligned with the rigorous standards of ISO certifications, aiming to deliver top notch components to its esteemed clientele. The journey commenced with the procurement of material from Gartland Foundry, followed by a thorough visual assessment to confirm the material’s accuracy, potential damages, and absence of contamination or rust. Upon approval, the material was stored securely to preserve its prime condition until the initiation of the machining operation.

The actual transformation of the Gear Cover Brace transpired on our highly precise 10A and 10B mills, meticulously adhering to a stringent machining sequence for optimal results. Our strategy entailed an initial roughing of all surfaces at B0 using a 1.5″ ASX400 Cutter. This was followed by the finishing of surfaces at B90 with the same cutter, then the finishing at B0. The creation of requisite holes was accomplished through Guhring Series 5511 carbide drills, employing a 10.32mm drill at B90 and a 15.0mm drill at B0. Post-drilling, we executed the chamfering of the holes at B90 using the Valenite Single Point Chamfer Tool and proceeded with tapping at B90 with the Guhring M12 X 1.75 Bottoming Tap. To ensure perfection, we removed any residual gating off the castings with a Guhring 3/4×3/4×1-5/8 Firex Helix Hog E/M tool.

Intensive inspections were executed throughout the machining process, using attribute gages for diameter measurements, variable gages for verifying milled face locations, and coordinate measuring machines (CMM) for high precision location measurements. Furthermore, visual checks for surface finish and possible defects were integral to our comprehensive inspection strategy at critical stages.

The culmination of the Gear Cover Brace machining process was marked by a final audit for correct identification and any visual irregularities. Following this, the refined components were meticulously inspected once more, packed, and accommodated in our secure storage facility, awaiting dispatch to our valued customer. Another extensive visual inspection prior to shipment ensured that the end product was accurate, devoid of damage, and perfectly aligned with all customer stipulations.

The intricate process of Gear Cover Brace machining finds applications in areas such as gear assembly, machine tool development, engine component manufacturing, and power transmission systems, among others.

The relevance of Gear Cover Brace machining spans across a broad spectrum of industries, including the automotive industry, aerospace industry, heavy machinery industry, marine industry, robotics and automation industry, agricultural machinery industry, and the mining equipment industry, to name a few.

Project Overview

Quality, Inspection, and Measurement Tools

  • Initial Receipt Inspection: Visually inspect the received material for correct type, damage, and contamination.
  • Dimensional Inspection: Use appropriate gages and/or CMM to measure dimensions after preliminary machining processes.
  • Surface Finish Inspection: Visually inspect machined surfaces for required finish and any visual defects.
  • Identification Check: Inspect for correct and present identification marks.
  • Final Audit: Conduct a final visual inspection to ensure that all aspects of quality are met.
  • Pre-Shipment Inspection: Prior to shipping, perform another visual inspection for correct type, identification, and any damage or contamination.

Equipment and Tools Used for Quality and Inspection Steps

  • Calipers and Micrometers
  • Attribute Gages
  • Coordinate Measuring Machines (CMM)
  • Visual Inspection Tools (Magnifying Glass, Illumination)
  • Surface Roughness Tester

Quality, Inspection, and Measurement steps are intertwined with Universal Manufacturing Steps to provide constant feedback and ensure that the produced components meet the required specifications. Each manufacturing step should be followed by a corresponding inspection step to verify that the part is ready for the next operation or for shipment.

Manufacturing Steps

  • Material Storage: Store the received material in designated areas.
  • Preprocessing: Perform any needed preprocessing operations on the raw material.
  • Rough Machining: Conduct initial machining operations to give the material its basic shape.
  • Detail Machining: Execute further machining processes for detailed features like holes, chamfers, etc.
  • Post-Processing: Includes operations like deburring, cleaning, etc.
  • Packaging: Pack the components properly for shipment or further processing.

Equipment and Tools Used for Manufacturing Steps

  • Milling Machine
  • Lathe
  • Drilling Machine
  • Tapping Equipment
  • Deburring Tools (e.g., Sanding Disk)
  • Cutting Tools (e.g., Endmills, Drills, Taps)
  • Workholding Fixtures

Each manufacturing step should be validated by corresponding quality and inspection steps from List 1 to maintain the desired quality levels throughout the manufacturing process.

Manufactured Components and Parts

  • Main Component (e.g., Gear Cover Brace)
  • Sub-components (e.g., Fixtures for holding parts during machining)
  • Hardware (e.g., Bolts, Nuts, etc.)