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Cell Manufacturing of a Steel Shock Absorber Assembly for the Defense/Military Industry

An important defense industry customer challenged Reliance Gear Corporation in the manufacturing and assembly of a steel shock absorber. This product is used in the state-of-the-art, battle proven suspension system for the all-terrain battle tank known as Merkava Mark 4. Reliance Gear was proud to accept this contract. After consulting with our customer, reviewing their specifications and drawings, we made state-of-the-art equipment investments for CNC turning and CNC milling centers, along with retrofitting PLC on an internal grinder. Our customer supplied the required heat treated steel forgings. We utilized the exceptional performance of our newly acquired equipment for CNC turning, drilling, tapping, and milling operations. Additional machining included spline broaching, part marking, deburring, and plating with black oxide. Our technicians employ a precise and monitored procedure to create a shock absorber assembly with an outside diameter of 248.1 mm, length of 130 mm, and having a 29 tooth 6/12 DP spline.

Our precise manufacturing results are documented and parts are magnetic particle inspected. When components are approved, we assemble, following a strict procedure ensuring the highest quality results. After completing assembly, performance is tested. Initial testing not only met the required criteria, it exceeded the OEM's performance to quality levels never witnessed before. The turnaround time for this project was eight months from concept to product, and we have secured a contract for manufacturing hundreds of these units per year for the next seven years.

To learn more about this project or to find out how our precision gear manufacturing can work for your company, please see the information below or contact us directly.

Steel Shock Absorber Project Highlights

Product Description
This product is used in the state of the art, battle proven suspension system for the Merkava Mark 4; an all-terrain battle tank.
Capabilities Applied/Processes
Primary:
CNC Turning
CNC Milling
Spline Broaching
I.D. Grinding
Secondary:
Assembly
Etching
Deburring
Black Oxide Coating
Overall Part Dimensions
Outside Diameter: 248.1 mm
Length: 130 mm
Spline Data
  • Number of Teeth: 29 (of 30)
  • D.P.: 6/12
  • P.A.: 30°
Tightest Tolerances
± 0.13 mm
Material Used
Heat Treated Steel Forgings - Customer Supplied
Material Finish
Black Oxide
In process testing/inspection performed
Dimensional Inspection, Visual Inspection
Magnetic Particle Inspection, Functionality Testing
Industry for Use
Defense/Military
Volume
Hundreds per Year
Delivery/Turnaround Time
8 Months - From Concept to Product
Standards Met
Customer Specifications - Proprietary
Product Name
Shock Absorber