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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

Reason For Design

Provided By: Remy International Incorporated.

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

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*

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.

Grooved Plate

Figures 1 & 2: Grooved plates used in apparatus. Four and three pin models shown.

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.

Hexagonal Chuck

Figure 3: Hexagonal Chuck.

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.

Adjustable Pin Grip

Figure 4: Adjustable Pin Grip.

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.

The Base Of The System

Figure 5: Vice Base

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.

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)

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)

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

Finite Element Analysis

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

Questions?