The paper talks about machining techniques and solution approaches while machining Aluminium grade gearbox housings. Mahindra’s next generation gearbox housings are made totally of Aluminium; along with the higher strength to weight ratio that comes with using Aluminium come highly optimized ribbed structures that aid in achieving the said strength. While machining such Aluminium structures, it is imperative that the clamping forces do not load the component in ways it is not intended to.
The paper talks about finish machining and proving out a semi-finished gearbox housing set (front, intermediate plate and rear) on a conventional Horizontal Machining Center (HMC). The input to the machine is the semi-finish housing that is already machined before with stock for finish operations.
This paper concentrates on the various aspects and parameters that need to be taken care of while proving out a component along with some techniques, solutions and unique approaches to problems that one might face during machining a similar component.
Figures 1 and 2Mahindra’s next generation gearbox housings in Aluminium. Left: front housing + intermediate plate assembly. Right: rear housing.
Rao, P. and Kulkarni, S., "Challenges in Machining Aluminium Transmission Gearbox Housings - a Structured Solution Approach Using Unconventional Means," SAE Technical Paper 2016-28-0211, 2016, https://doi.org/10.4271/2016-28-0211.
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Challenges in Machining Aluminium Transmission Gearbox Housings - a Structured Solution Approach Using Unconventional Means
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Figures 1 and 2