2017-2020
Manufacturing
Cornell Baja
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The following page is mainly to showcase some of the parts I fabricated on the Baja team. This was a central part of my experience as I would work in the machine shop 6 days a week and would come to Cornell early during winter break to help complete all of our parts. I am very proud of how I was able to make all of these parts, and pass along the skills I learned to other engineers.
Full Spread of Gearbox & Half-Shaft Components from 2019-2020 Season
Electrodes used to plunge EDM spline torque transfer profiles into gears
Plunge EDM Process occurring on gearbox shaft
2019-2020 Gearbox casing on fixture in CNC
Steel CV insert tracks machined in custom soft jaw chuck fixture. Even clamping provided reliable work-holding and eliminated risk of crushing inserts. Fixturing also enabled half-thou passes to dial in fit
Large piece of stock loaded up on rotary fixture in CNC
Half-shaft inserts bar fed on CNC Lathe and pre-machined Gearbox Casings with precision bearing surfaces
Gear set blanks and pinion shafts prior to tooth hobbing
Final gear in hobbing machine
2019-2020 Unsprung Corner assembly mock-up with 3D-Printed Upright and sectioned wheel
CVT Primary Pulley, partially machined on CNC
Overrunning clutches machined on CNC Lathe
Normalized 9310 Steel, to reduce residual stresses before machining
2018-2019 Final Gear Set after hobbing and heat treatment
CVT Secondary Pulley on CNC, seated in machining fixture