Sand Casting, Metal Forging & CNC Machining for Industrial Gearboxes
When an agricultural equipment manufacturer needed a reliable replacement for an existing right-angle gearbox, they turned to The Federal Group USA to reproduce the complete assembly while maintaining the original dimensions, fit, and performance.
The project required several different manufacturing processes to produce the gearbox components, including sand casting, metal forging, and CNC machining.
The Challenge: Replacing a Legacy Industrial Gearbox
The customer’s existing gearbox manufacturer was no longer able to produce a right-angle gearbox used in agricultural equipment. Replacing it with a standard design would have required modifications to the customer’s existing machinery, creating additional costs, engineering work, and potential downtime.
The customer needed two gearbox configurations—clockwise and counterclockwise—that would maintain the original mounting dimensions, interfaces, and performance characteristics. The replacement components also needed to work with the customer’s existing equipment without significant modifications.
Developing a Manufacturing Solution
TFG evaluated samples of the existing gearboxes and used dimensional measurements and 3D scanning to establish the geometry and critical dimensions of the components. This information was used to develop CAD models and manufacturing drawings that could be used for production.
With the design requirements established, TFG selected the appropriate manufacturing process for each component based on its geometry, strength requirements, and dimensional tolerances. The project combined sand casting, metal forging, and CNC machining to produce the major gearbox components.
Sand Casting for the Gearbox Housing
TFG leveraged its experience sand casting components for agricultural equipment to produce the gearbox housing’s complex geometry and meet the strength requirements of the application. The cast housing was manufactured to the required dimensions and incorporated the mounting features and interfaces needed for installation.
An industrial corrosion-inhibiting coating was then applied, and the customer’s logo was incorporated into the housing. Sand casting provided an efficient solution for producing the durable housing required for the agricultural equipment application.
Metal Forging for the Gear Components
The gearbox gears required strength and durability to withstand the loads associated with power transmission. TFG manufactured the gear blanks using metal forging before machining them to their required dimensions.
Forging provided a strong starting point for the gear components, while subsequent machining brought the gears to the dimensional requirements necessary for proper operation within the gearbox assembly.
CNC Machining for Precision Components
The gearbox included shafts with several critical machined features. TFG used CNC machining to produce retaining ring grooves, sealing surfaces, threads, bearing-fit surfaces, and other precision features required on the shafts.
CNC machining provided the dimensional accuracy and repeatability needed for these components to interface properly with the gears, bearings, seals, and other gearbox components.
Complete Gearbox Assembly and Testing
In addition to manufacturing the primary components, TFG facilitated the procurement of required buyout components, including fasteners, bearings, seals, and snap rings. The individual components were then assembled into complete gearboxes.
Each component and completed assembly underwent testing to verify dimensional and performance requirements. Once testing was complete, the customer inspected the finished gearboxes for proper operation and excessive noise.
The completed gearboxes were installed onto the customer’s original agricultural equipment and interfaced successfully without requiring significant modifications.
The Result: A Reliable Replacement Manufacturing Solution
By combining sand casting, metal forging, and CNC machining, TFG was able to manufacture the major components required for a complete replacement gearbox while maintaining the original design requirements.
The customer avoided the time and expense associated with modifying existing equipment to accommodate a different gearbox design. The completed assemblies provided a direct replacement solution while giving the customer a manufacturing partner capable of supporting future gearbox components and replacement parts.
Looking for a Manufacturing Partner for Custom Agriculture Components?
Whether you need gearbox housings, gears, shafts, brackets, hubs, pulleys, hydraulic components, or other custom agricultural machinery parts, TFG USA can help identify the right manufacturing solution for your application.
