Helicopter gearbox housing

Task

• Complex magnesium machining
• 67 bores
• 31 fits
• 5 thread dimensions
• Specific aerospace and military
  requirements
• Starting basis was only the 2-D
  drawings
  
  

Solution

• Turnkey implementation
• CAD 3-D model UG
• Construction and manufacturing
  device
• Tool design
• CAM and CNC programming
• Simulation in real time
• Collision consideration
• Tool assembly including balancing
  and coding
• Assembly and commissioning
  of the device
• Running-in of the tools (136 tools)
• Problem-free realisation in only
  4 months
• Reduction of the cycle time from
  32 h to 5.5 h
• Reduction of the clamping
  positions from 6 to 3
• Consequent reduction of the
  equipment and personnel
  requirement by > 50 %
• Reduction of the total manufacturing
  costs by > 60 %
• Maximum process reliability through
  the use of ultra-modern tools and
  clamping devices