My senior project for the Baja SAE design competition was to design, build, and test our gearbox for the 2017 California competition. The full design report is available upon request.
Design: Was done with Solidworks and all proofing was done with Solidworks FEA and hand calculations.
Pictures to come
Build: All Machining was done on a Haas 3 axis mill..
First the operations inside and out, left and right were setup in FeatureCAM to generate tool paths.
Then the first step in manufacturing was getting the stock prepped.
Next the inside pockets were cut in both the left and right side cases.
Once the pockets were cut out then the stock flipped over and bolted to the fixture plate so the second operation could be done on both sides.
The outside of each case was then machined.
Next a gasket was laser cut to seal the two halves.
Then the gears, shafts, and bearings and assembled.
Test: