Western Machine Works reverse engineered and manufactured a new shaft for a motor armature. The old shaft was severely damaged and repairing it was not a viable option. Western Machine Works’ engineering group took on the challenge of generating the manufacturing drawings and verifying all critical fits. The armature bore was precision machined to 100% concentricity and the new shaft was installed with the required interference fit. 

Project:

• Part: 3000 HP Motor Armature

Challenge:

• Existing shaft was damaged beyond repair.
• No detailed manufacturing drawings exist.

Engineered Solutions:

• Dimensionally inspect existing shaft to generate manufacturing drawings.
• Work with the customer to correctly dimension all critical fits.
• Cut off the existing shaft on both sides of the armature.
• Set up armature in VBM to bore out the remaining shaft.
• Machine armature bore to 100% concentricity.
• Manufacture new shaft out of 4140 alloy steel.
• Freeze new shaft in liquid nitrogen and install to the armature with interference fit.
• Set up armature and shaft in the lathe, and machine slip rings to 100% concentricity.
• Balance to ISO G1.0 specification.
• QC to inspect and approve prior to shipping.

Result:

With precision machining and reverse engineering, the new shaft fit in the armature perfectly.

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