FSAE Wheel Hubs Manufacturing

I manufactured aluminum wheel hubs for the 2018 vehicle using a CNC lathe and mill. I held a tolerance of .0005" on critical bearing surfaces; each hub has one slip fit and one press fit bearing. For the mill operations I experimented with different fixturing methods, finding that a jig plate was more reliable than soft jaws and avoided the risk of deforming bearing surfaces. I used the 4th axis on a HAAS VF2 to create radial holes in the shaft for a cotter pin to ensure positive locking of the wheel nut. The rear hubs were sent out of house to be splined using a wire EDM. The hubs were then masked, anodized red, and assembled into the uprights.