Problem
Tight tolerances of chamber dimensions for even load distribution on the bevel gear teeth; any deviation in production from the target geometry may cause negative backlash and premature failure of the gearbox.

The axis of the differential bevel gears must run through the center of the ball of the output bevel gears, otherwise the load distribution is asymmetrical and the service life of the gearbox and the running behavior are not ideal.  

Solution
Machining of the ball including the axis bore of the differential bevel gears in a single set-up 

• Construction of special tools required
• Matching of clamping devices, tools, and processes 
• Post process measurement in automation – quality control loop
• Solution for split and one-piece EGG developed and in series