Axle Manufacturing Datum Alignment and Vertical CNC Machining
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Solution Overview
Problem
The existing method for manufacturing vehicle axles involves multiple welding operations that cause distortion and metal fatigue, leading to misalignment and increased manufacturing costs due to the need for straightening and extensive machining of large, assembled axles, which requires significant space and expensive machinery.
Innovation Solution
The method involves creating datums on the axle housing before assembly, welding brake flanges and spindles to these datums, and using a dial indexing table to orient the axle vertically for CNC machining, allowing for precise alignment and machining without the need for post-assembly straightening or extensive machining of large assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple welding operations are performed to assemble the axle components, then the axle can be constructed with proper alignment of spindles and flanges, but the welding heat causes distortion and metal fatigue requiring straightening operations
Solution Approach 1:
The patent applies preliminary action by creating precise datums on the axle housing before welding operations begin. These datums serve as reference points that guide the welding process, ensuring proper alignment of spindles and flanges is achieved during assembly rather than requiring post-welding straightening operations. This preliminary establishment of reference geometry prevents distortion issues before they occur.
2Manufacturing precision
If the axle is machined after complete assembly to achieve precise alignment, then the spindles and flanges can be properly aligned, but the large size and weight of the assembled axle make it difficult to manipulate and machine
Solution Approach 1:
The patent applies segmentation by dividing the machining operations into two stages: first, machining individual components (spindles, flanges, axle housing) separately when they are smaller and easier to handle; second, assembling these pre-machined components using datum-based alignment. This eliminates the need to manipulate and machine the complete assembled axle, which would be extremely difficult due to its large size and weight.
3Manufacturing precision
If extensive machining operations are performed on the large assembled axle, then precise alignment can be achieved, but the process requires large floor space and expensive machinery
Solution Approach 1:
The patent applies preliminary action by creating precise datums on the axle housing before assembly. These datums enable accurate positioning and alignment of components during assembly, eliminating the need for extensive post-assembly machining operations. This preliminary establishment of reference geometry allows precise alignment to be achieved through assembly rather than through space-consuming machining operations on the complete axle.
4Ease of manufacture
If the axle is machined in horizontal orientation, then machining operations can be performed, but the process requires more floor space and results in higher manufacturing costs
Solution Approach 1:
The patent applies inversion by changing the conventional horizontal machining orientation to vertical machining orientation. The axle housing is positioned vertically on the dial indexing table, allowing machining operations to be performed from the top. This vertical orientation reduces the floor space footprint of the machining operation while maintaining manufacturing capability, effectively inverting the traditional horizontal machining approach.
Data Source
AI summary
A datum is created in an axle housing. A finished brake flange is welded to the axle housing with reference to the datum to make an axle sub-assembly. The axle sub-assembly is fixed to a first part of a machine. A finished spindle is supplied to a second part of the machine. The spindle is welded to the axle sub-assembly with reference to the datum. A dial indexing table is rotated to a first position. An axle is placed on the dial indexing table with its longitudinal axis oriented vertically. The dial indexing table is rotated to a second position, wherein the axle aligned with a CNC machine. A machining operation is performed on the axle with the CNC machine. The dial indexing table is rotated to a third position. The axle is removed from the dial indexing table. An axle and an apparatus for manufacturing an axle are described.