Manufacturing experience in transmission gear projects: a manufacturing process combining casting and machining
Table of Contents
- Manufacturing experience in transmission gear projects: a manufacturing process combining casting and machining
- What kind of company is Valeo ?
- Cooperation on the Gearbox Project
- Design Considerations for Each Process in the Gearbox Project
- The second contact was a meeting with their engineering team.
- Key communication issues in the gear transmission project
- Project progress of the transmission gear
- A detailed explanation of the benefits of manufacturing transmission gears using a combination of casting and machining processes.
- Elimold, your cost-effective foundry and machining service provider
- Conclusion
Our company’s official email address frequently receives spam from well-known companies. This is usually because we’ve subscribed to their websites, or perhaps they’ve just obtained our email addresses. We rarely pay attention to these emails, especially after we’ve learned the true nature of spam. So, our reaction when we received an email from the Valeo Group in 2017 was predictable. They were asking if we could supply them with custom parts (including: transmission gears, piston rings, crankshaft journals, brake calipers , etc.) . First, this was n’t the first time our company had received such emails. And previous emails hadn’t brought any benefit. Our sales team completely dismissed them as spam. Why would a large company like Valeo contact us ? It seemed utterly incomprehensible at that time . But what happened next surprised us greatly.
What kind of company is Valeo ?
Valeo is a renowned manufacturer of automotive parts . Originally a French company headquartered in Paris, it has rapidly expanded to other countries since its founding in 2009. Today, Valeo is a multi-billion dollar global automotive company, supplying a wide range of products to automakers and the market. It prides itself on being a technology company with global automaker partners. It was one of their subsidiaries that contacted us seeking collaboration. Now you should understand why I initially didn’t believe it was true. Valeo is a company dedicated to advancing intelligent driving and also a provider of top-tier automotive components.
Cooperation on the Gearbox Project
Valeo’s project is about their gearbox . It’s a new project they’ve just launched. So, let’s take a look at the specifics of this project.
The project involved casting followed by machining. This was entirely new to them, and the requirements for detail were extremely stringent. They set specific precision and durability requirements that had to be met. Therefore, all products had to pass speed and wear tests, and all needed to be tested using a coordinate measuring machine (CMM). Based on our past experience, this process was very difficult. We needed to meet with the R&D team, a total of three meetings, before finalizing the plan. Ultimately, we developed a feasible solution and redrew a quotation. But as before, I felt this might be the end of the deal, so I didn’t have high hopes.
Design Considerations for Each Process in the Gearbox Project
Before proceeding with any step of the transmission gear project, our engineering team compiles design considerations and determines the most suitable process for the project’s needs. We primarily focus on the design optimization issues required for the casting and machining processes involved in this project.
Machining Design for Variable Gear Project
The first step in designing the machining of transmission gears is to find suitable materials, optimize the geometry of parts for key machining processes, and minimize the need for secondary machining. Designers should prioritize features that are easy to machine and can be implemented quickly with little or no effort. However, designers must ensure that material inventory is sufficient to cover machining allowances.
Casting design for variable speed gear project
Casting design for transmission gear projects involves precise consideration of parameters such as block shape, draft angle, and material flow characteristics. Designers must research creative molds that allow material to flow efficiently and significantly reduce the chance of defects, namely porosity, shrinkage, or deformation. Considering the draft angle and fillets at the part’s forming location facilitates easy disassembly and reduces the likelihood of casting defects. It is also recommended to consider the location of boundaries and heights to ensure uniform filling and solidification of the casting. Through optimized casting design, manufacturers can produce powerful parts with minimal defects and production costs.
The second contact was a meeting with their engineering team.
In October of the same year, we received another email from Valeo. This time, they informed us that they were about to travel to China and that we were a potential supplier for their project. This was quite different from the previous situation. Valeo took follow-up action this time, which ultimately changed the course of the project , and the material was determined to be ALSi10Mg alloy . In the following weeks, their purchasing director visited us in person. This visit was crucial to the project. After the visit, they highly praised our factory and processes, and even commended our technical staff. During the visit, we identified a series of technical issues and jointly proposed possible solutions. They returned satisfied. So, this time we were not disappointed. Shortly afterward, we received a formal order confirmation from Valeo, which delighted us.
Key communication issues in the gear transmission project
In addition to learning about our factory, this meeting allowed both parties to have in-depth exchanges and finalize various project issues that had been discussed in previous emails. The main points are as follows.
Cost considerations
They stated that the gear transmission project involves large-scale production, therefore, the cost of each part in our manufacturing process cannot be too high. However, both casting and machining processes require labor and time, and since each gear transmission component needs to be operated individually, this results in high costs.
For mass production, casting is generally more economically feasible, as it reduces material and labor costs per part. While the initial cost of setting up molds is higher, casting helps achieve cost-effective measurement when manufacturing many parts consistently. Therefore, in selecting the production method for transmission gears, we adopted a method of casting first, followed by secondary machining using CNC machining, which reduced the overall cost of the project.
Production volume
We then determined the specific production volume for the gear transmission project to be 10,000 units per month. Casting excels in this high-volume production project because the casting process can be highly automated after mold production, allowing for the production of a large number of parts with minimal individual machining. For companies seeking to regularly manufacture large quantities of replicated parts, casting is the most suitable production option due to its high-volume production capacity. For medium to low-volume production, machining would be our preferred choice, as its flexibility and faster setup time are important considerations. Machining is used for efficient production of small batches or prototypes. However, due to the high precision requirements of this product, we used a casting-first, precision-machined approach in the gear transmission project.
Material properties
The final decision on the ALSi10Mg alloy material for the transmission gears also played a crucial role in determining the optimal manufacturing method of casting combined with machining. While a wide variety of materials can be used to manufacture transmission gears, the use of ALSi10Mg alloy helps overcome the casting challenges of materials that are difficult to cast. By combining casting with precision CNC machining, complex shapes and minute details can be created. This can be an advantage when designing objects that require specific material parameters.
Dimensional accuracy and surface finish
Final precision and surface finish are critical parameters that are always required in the manufacturing process of most custom parts. Machining is characterized by excellent parameters such as dimensional accuracy and surface quality. Its tight-tolerance cutting tools and smooth machined surfaces not only meet the needs of many demanding industries but also exceed their standards.
Casting can largely achieve standard dimensions and surface quality, but may sometimes have slight errors, and the finish may be better than machining. On the other hand, recently introduced advanced casting technologies, namely investment casting or pressure sand casting, ensure that casting no longer requires the precise dimensions and smooth surface finishes required for specific applications.
Therefore, since customers not only have high requirements for product precision, but also for product surface finish, we ultimately improved the surface finish and precision of the gear transmission project through machining and some surface treatment processes.
Project progress of the transmission gear
After multiple meetings and confirmations, we finally secured the gearbox project. The following is the project’s workflow.
During the production of the ALSi10Mg alloy casting mold, we encountered numerous problems, such as power outages, substandard materials, and issues with product precision and the accuracy of post-processing fixtures. It’s important to understand that this project had extremely stringent requirements for detail. Fortunately, our quality control team meticulously inspected all products and processes and resolved all issues promptly. Therefore, we were able to deliver samples within the agreed-upon timeframe.
The gearbox sample has been sent to the customer’s company. The customer tested the sample and confirmed that it met their requirements. They tested every aspect of the sample, and it passed all the necessary tests perfectly. Therefore, they are very satisfied with the sample. This is thanks to the efforts of our entire team.
About two months later, we collaborated with Valeo on another project. Since then, we’ve continued to work together on various products. The first project was a milestone. They greatly appreciated the quality of our work and have therefore maintained a continued partnership with us.
Furthermore, we always listen carefully to their suggestions and requests for adjustments. We also consistently deliver products within the stipulated timeframes. In other words, we have never delayed delivery. Of course, we have encountered some problems. But no matter what problems we encounter, we always resolve them and complete the work.
Therefore, Valeo has never raised any complaints about the quality of our work. On the contrary, they have always given us 100% praise. They consistently commend our processes and the outstanding work of our team. This recognition has continued over the years, even as our collaboration has grown. Sometime in 2018, our relationship with Valeo improved due to the company’s business growth .
A detailed explanation of the benefits of manufacturing transmission gears using a combination of casting and machining processes.
Manufacturing transmission gears using a combination of casting and machining techniques has several advantages:
Precise and accurate
Machining results in an unparalleled sequence of processes in manufacturing. Utilizing a variety of precision technologies, including milling, lathes, and grinding machines, it produces ultra-precise tolerances and surface finishes. This level of accuracy is crucial for gear transmission projects, as even slight deviations from markings can be dangerous in many cases. Machining is characterized by its ability to produce parts with complex shapes and diverse features, meeting the most complex requirements, and ensuring consistent and precise production processes.
Multifunctionality of materials
One of the main attractions of this technology is its ability to process a variety of materials. The transmission gears utilize special alloys. The development and combination of two processing techniques are designed to meet the specific requirements of these different materials. This adaptability is a key factor in enabling the manufacture of high-precision transmission gear products. It allows manufacturers to add various details to their transmission gear products.
Customization possibilities
Machining combined with casting processes brings a wealth of diversity and limitless customization possibilities to gearbox projects. Parts can then be precisely manufactured to meet specific customer applications. Whether developing new models (including the unique manufacturing of individual components) or producing small parts with specific functions, machining allows for flexible, individualized responses. Through the application of CNC (Computer Numerical Control) technology and advanced software, machinists can now quickly program complex shapes and patterns, adapting to minor iterations and design changes with minimal effort.
Minimal material waste
On the other hand, the combination of machining and casting is unique because the proportion of material waste resulting from this combination of two manufacturing processes is minimal. By using subtractive processing to create metal parts by removing excess material from solid blocks, the utilization of raw materials is maximized while reducing the adverse environmental impact of production. Furthermore, recycling scrap and slag minimizes waste, making the combination of machining and casting a viable option for gearboxes.
Elimold, your cost-effective foundry and machining service provider
Elimold offers precise custom casting and CNC machining services with fast turnaround times. You can customize precision parts of various sizes, from a few grams to your preferred dimensions. Our experienced staff and engineering, strategy, and creative experts can complete your projects to your specifications. From prototyping to mass production, we offer the most affordable service. Our workshop is equipped with automated machines and robots built with futuristic technologies. We can achieve tolerances as low as ±0.004 inches (0.1 mm) for your custom parts. We are ISO 9001:2015 certified and manufacture your custom parts according to industry standards.
Conclusion
The combination of machining and casting offers unique advantages and considerations in manufacturing variable speed gear products. Machining provides unparalleled precision, material versatility, customization possibilities, and minimal material waste, making it ideal for applications requiring high-quality, complex parts in medium to low production volumes. On the other hand, casting excels in its ability to mass-produce variable speed gears, its feasibility with complex geometries, its cost-effectiveness in high-volume production, and its wide range of material choices, making it ideal for companies with high demands for standardized components. Contact Elimold to learn which technologies are best suited for you. However, if you know of any products best suited for your project, we can meet your needs. Get a quote.