DESIGN & MANUFACTURING OF PLATE STARTER CLUTCH HUB FOR TWO WHEELER -A REAL TIME PROJECT By S.Ganapathi subramanian ( ) T.Karunanithi ( ) S.R.Manoj ( ) M.Ravichandran ( ) Under the guidance of Mr.S.Gopikannan M.E, MBA., Stream:Production Batch no:16 1

COMPANY PROFILE:- APPLIED ENGINEERING & TECHNOLOGY (P) LTD., AN ISO 9001:2000 CERTIFIED COMPANY. ADDRESS: OLD NO.5,NEW.NO.99,SOUTH PHASE,AMBATTUR INDUSTRIAL ESTATE,CHENNAI,INDIA TEL: & , MOB: FAX: WEBSITE: 2

MANUFACTURER OF PRESSURIZED METAL COMPONENTS PROMOTER: Mr.D.KARUNAMOORTHY (B.E.,) RANGE OF PRODUCTS & CLIENTS: petrol tank collar- Royal enfield motors, Air cooling system-cooling fan case- Dynamic motors, Rear axis sprocket support plates- TVS suzuki bike, Online post process monitoring of centre distance measurement- TIDC INDIA. MACHINERIES/EQUIPMENTS: Centre lathe, Radial drilling m/c, Universal milling m/c, Surface grinding m/c, 250ton power press with pneumatic clutch, 60ton mechanical press, CNC lathe, etc., 3

STATEMENT ABOUT THE PROBLEM:-  Plate starter clutch hub is a part of starter motor in a two wheeler self start engine.  We are going to design, develop & manufacture the same for a newly designed engine developed by one of the largest two wheeler manufacturer.  The process should satisfy the customer requirements. 4

REASON FOR CHOSEN THIS TOPIC:-  Now a days,without automobiles it is not possible to tranfer anything to any place in a quick manner.  Each and every components of an automobile requires various process sequences and complicated design features and takes long time to manufacture.  There are so many practical difficulties occuring while design, developing & manufacturing a new product.  While involving ourselves in this process we are able to get an minimum exposure of these process & industrial works.  And also to improve our knowledge yet further, we have chosen this topic. 5

TABLE OF CONTENTS SL.NO.TITLE Project summary Product details Product manufacturing analysis Tool design Tool manufacturing Product manufacturing Inspection system 6

PROJECT SUMMARY:-  Plate starter clutch hub is a part of starter motor in a two wheeler self start engine.  One of the largest two wheeler manufacturer is going to launch a new two wheeler.  According to their two wheeler requirements, we are going to manufacture the plate starter clutch hub. 7

PRODUCT DETAILS:- Raw material : cold rolled carbon alloy (CRCA). Raw material availability : 1)Sheet Standard size – 2500×1250mm. check for flatness and then cut it into small strips by considering economic factors. 2)coil: Rolled form Remove the coil in decoiler and level the coil and then cut into small blankets. 8

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PRODUCT MANUFACTURING ANALYSIS:- SEQUENCE OF OPERATIONS: 1.Blank and draw 2.Parting off 3.Piercing 4.Hole flanging 5.Side hole piercing 10

TOOL DESIGN:- Calculating developmental size: From the customer design calculate the die specification using two methods: 1.Design softwares 2.Geometrical calculations. Calculating load condition: By considering the material and its area, calculate the necessary load required to do the processes like blanking, piercing, etc., 11

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TIME LINE:- PROCESSJAN 1-15JAN 16-31FEB 1-15FEB 16-28MAR 1-15 Product manufactur ing analysis Tool design Tool manufactur ing Product manufactur ing Inspection & record 13

THANK YOU. 14