Wire Erosion Project – Power Press Drive Shaft Repair

Date: July 2016

Type of Work: Repair

Client Requirements:

The Helical gears at both ends of the shaft were damaged.  As a result the damaged portion of the gears needed to be removed. These then had to be replaced with steel inserts. This is quite an intricate task as in this situation it is essential that the new inserts are a good fit while also ensuring that the necessary linking between all teeth is maintained.

Work Carried Out:

Because the gears are helical, replacement is not straight forward due to its characteristics. The first step to fixing the problem was the sub-can removal of the damaged teeth portion.  Accurate measurements of the portion removed were then taken using our new Faro Arm.  The Faro Arm is one of the world’s most innovative portable measurement solutions and bestselling measurement arm.  Cheshire Wire Erosion prides itself in keeping up to date with developments in the world of engineering and because of this we recognise the importance of ensuring we use the very best, and most up to date technology. This piece of technology enables us to carry out accurate dimensional analysis. With the accurate measurements we had obtained from using this technology, templates for the front and rear faces were wire eroded.  These were made to ensure that the correct size, fit and timing with adjacent remaining teeth, was maintained.  This had to be repeated for both gears at opposite ends of the shaft.  Due to the material costs and wire erosion cutting rates, aluminium inserts were firstly wire eroded to all the sizes, and fits etc that we had achieved earlier.  These aluminium blocks in conjunction with timing gauges that sat on top of the old and new teeth confirmed a perfect job!  All that was needed now was to cut the finished inserts from steel, once again checked with the timing gauges and Faro Arm – see photos.

The result…the customer was “over the moon

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