1 me 462 capstone design sponsor: remy international inc. iupui design team #1 proposal presentation...
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ME 462 Capstone DesignSponsor: Remy International Inc.
IUPUI Design Team #1Proposal Presentation
May 3rd 2007
Matt SchonauerIbraheem Nezamuddin
Martha TadesseBrandon HarvilleNathanial Greene
Starter Drive Over Stress Fixture Design
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Overview
Reason For Design Design Requirements Design Concepts Finite Element Analysis Design Evaluation Summary
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Reason For Design
Provided By: Remy International Incorporated.
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Customer Requirements Versatility
Adjustability
Strength: Withstand large amounts of
force Longevity
Cost Effectiveness
Design RequirementsEngineering Requirements Versatility:
Works with existing part line
Adjustability: Able to test different size starter
drive trains Strength:
Long time before damage occurs High material toughness
Longevity: Corrosion resistant (black oxide
sprayed)
Cost Effectiveness: Low number of parts used Use existing power supply
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Design Concepts
The following are the components of the different tests: Grooved Plate Hexagonal Chuck Adjustable Pin Grip The Base of The System Bending Moment Assembly*
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Grooved Plate Used to grasp the drive shaft from
the pin side. It is designed for the testing of the
drive shaft. It was designed to fit different sizes
of drive shafts. The grooved plate actually will be
made in two different configurations.
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Grooved Plate
Figures 1 & 2: Grooved plates used in apparatus. Four and three pin models shown.
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Hexagonal Chuck
Used to grasp the armature shaft. The armature shaft will be ground
down and inserted into the hexagonal chuck.
The chuck of the torsion machine will grasp the outside of the chuck itself.
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Hexagonal Chuck
Figure 3: Hexagonal Chuck.
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Adjustable Pin Grip
Used for the output shaft test. Method in which a moment can be
applied to the clutch housing. The supports at the pin holes will
be fixed, and the moment will be applied from the torsion machine at the triangular chuck.
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Adjustable Pin Grip
Figure 4: Adjustable Pin Grip.
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The Base Of The System
Will hold a vise. Will attach to the top by two bolts.
This vise will grasp the ring gear casing, thus causing the ring gear to be fixed. The table will be welded together from one inch hollow steel tubing.
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The Base Of The System
Figure 5: Vice Base
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Bending Moment Assembly
Assembly is used for applying bending moment on starter drive.
Assembly will use existing apparatus at Remy for applying downward force.
Assembly will convert downward force into moment.
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Bending Moment Assembly
Figure 6: Bending Moment Assembly
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Finite Element AnalysisNum ber of Nodes vs Maxim um Deflection
3.70E-06
3.75E-06
3.80E-06
3.85E-06
3.90E-06
3.95E-06
4.00E-06
4.05E-06
4.10E-06
0 5000 10000 15000 20000 25000 30000
Num ber of Nodes
Max
imu
m D
efle
ctio
n (
m)
Num ber of Nodes vs Maxim um Von Mises Stresses
4.30E+06
4.40E+06
4.50E+06
4.60E+06
4.70E+06
4.80E+06
4.90E+06
0 5000 10000 15000 20000 25000 30000
Num ber of Nodes
Max
imu
m V
on
Mis
es
Str
esse
s (P
a)
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Finite Element Analysis
Maximum Deflection vs Number of Nodes
1.06E-08
1.08E-08
1.10E-08
1.12E-08
1.14E-08
1.16E-08
1.18E-08
1.20E-08
1.22E-08
0 5000 10000 15000 20000 25000 30000 35000
Num ber of Nodes
Max
imu
m D
efle
ctio
n (
m)
Maximum Von Mises Stresses vs Number of Nodes
0.00E+00
1.00E+05
2.00E+05
3.00E+05
4.00E+05
5.00E+05
0 5000 10000 15000 20000 25000 30000 35000
Num ber of Nodes
Max
imu
m V
on
Mis
es
Str
ess
(Pa)
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Finite Element AnalysisNumber of Nodes vs Maximum Deflection
0.00E+00
5.00E-08
1.00E-07
1.50E-07
2.00E-07
2.50E-07
3.00E-07
3.50E-07
4.00E-07
4.50E-07
5.00E-07
0 5000 10000 15000 20000 25000 30000 35000
Num ber of Nodes
Max
imu
m D
efle
ctio
n
Number of Nodes vs Maximum Von Mises Stresses
0.00E+00
2.00E+05
4.00E+05
6.00E+05
8.00E+05
1.00E+06
1.20E+06
1.40E+06
1.60E+06
1.80E+06
0 5000 10000 15000 20000 25000 30000 35000
Num ber of Nodes
Max
imu
m V
on
Mis
es
Str
esse
s
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Finite Element Analysis
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Design Evaluation
Engineering Targets Competition Our Parts Delighted/Disgusted Criteria
Versatility:
Works with existing part line No Yes Yes / No
Adjustability:
Able to test different size starter drive trains No Yes Yes / No
Strength:
Long time before damage occurs 53 C Rockwell60C
Rockwell 60C Rockwell / 30C Rockwell
High material toughness 7,000 ft-lb 10,000 ft-lb 10,000ft-lb / 5,000ft-lb
Longevity:
Corrosion resistant (black oxide sprayed) Yes Yes Yes / No
Cost Effectiveness:
Low number of parts used 4 0 0 / 5
Use existing power supply No Yes Yes / No
Figure 7: Engineering Targets Evaluation.
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Summary
Overview Reason For Design Design Requirements Design Concepts Finite Element Analysis Design Evaluation
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Questions?