Gear Wheel and Output Shaft Reverse Engineering & Manufacturing

PROJECT: Gear Wheel and Output Shaft Reverse Engineering & Manufacturing

LOCATION: GREECE

CLIENT: SEAJETS – Vessel CHAMPION JET II

DURATION OF REPAIRS: 15 Days

Gear wheel stock material prepared for teeth cutting

New out-put shaft fabrication on our 5-axis milling and turning machines, based on reverse engineering of the sample shaft

Gear teeth cutting by milling diminishes the need of special HOB cutting tools and reduces manufacturing time drastically

Gear wheels up to 1200mm diameter can be fabricated on our full 5-axis milling and turning machines

During voyage, vessel CHAMPION JET II a high speed passenger catamaran, suffered reduction gear box failure on one of its two propulsion engines. The gearbox was dismantled and all components arrived to our workshop for inspection and assessment. The works included the following stages:

Rigorous inspection, measurements and damage assessment
Reverse engineering of the gear wheel and output shaft
Manufacturing of new gear wheel on our 5 Axis CNC DMU65FD
Manufacturing of new output shaft on our 5 Axis CNC DMU125FD
Assembly