2-Speed Gearbox

Project Overview

The gearbox housing was machined from a 6061 aluminium billet on a 3-axis CNC mill, with G-code generated entirely in Fusion 360 CAM. Spur gears were cut on a gear hobbing machine and hardened. The project required close attention to tolerancing at every bearing seat and gear mesh to ensure smooth, low-noise operation.

Key Highlights

• ±0.01 mm tolerances achieved on all critical bearing fits
• Full CAM program written in Fusion 360 — 14 setups
• CMM inspection report produced for all critical dimensions
• Tested under sustained 200 Nm input torque with no failure
• Complete GD&T drawing set with stack-up analysis