Drive Sprocket
Overview
Focus:
Quality ControlIndustry:
IndustrialDimensions (mm):
95 x 66Weight (g):
726Sample Run
End-to-End
Simulation
Prototyping
Complex Machining
Quality Control
This is a drive sprocket made of IC 8620 low alloy steel, which is used in a conveyer chain machine at John Deere’s facility in Germany. It is used in the manufacture of agricultural tractors. We can deliver the components within a 6-8 week turnaround time, and have been collaborating with John Deere for more than 20 years.
Concept Development
Texmo Blank’s engineering team was fully involved in the technical discussions surrounding the development of this casting with the customer. We provided input into the design process which enabled the customer to make changes to the product design and the manufacturing tolerances. A major example of our input here was in the modification of the design in line with Texmo Blank’s die-manufacturing capabilities.
Simulation & Risk Identification
We used casting simulation software to predict defects taking place during the solidification process. Defects checked for included shrinkage and non-fill; any such potential issues that do become apparent through simulation can be avoided through modifying the geometries before beginning the full production run.
We also use a technical feasibility sheet, as well as failure mode and effect analysis to evaluate potential risks and confirm manufacturing feasibility.
Prototyping
We also carried out prototyping, making a low volume sample run from a basic aluminium-injected tool. This was a cost-efficient and fast way to create samples for the customer to check and approve.
During the prototyping phase we encountered a problem with a key way feature due to the fixturing. We solved this by slightly modifying the fixture concept.
Manufacturing Processes
For this component we used our ceramic mould investment casting process, with a robotic system. For the machining we used turning and grinding machines. The most difficult parts of this process were the key way slot machining and the final heat treatment, however we were able to overcome challenges posed by these stages.
Our gating, assembly method and consistency of manufacturing processes ensure quality and reliability. We also carry out 100% visual inspection and hold specialised certifications that guarantee process stability.
Quality Control
We maintained critical dimensions for this component using machining after heat treatment, which meant we could control them during regular production.
Critical dimensions included: key way slot dimensions of 8 +/- 0.03mm; bore diameter of 30.02 +/- 0.02mm; and a tolerance of 33.3 +/- 0.1mm.
A special plug gauge was made to ensure the critical key way slot dimensions. Our production part approval process assures quality and we carry out 100% visual inspections on all parts before shipping as a further means of quality control.
Get In Touch
We take pride in building successful, long-term relationships with our clients, because their reputation is our priority.
If that sounds like an investment castings partner you’d like to work with, you can book an introduction call with our friendly and knowledgeable New Relations Team — in a language and time zone to suit you.