1. 1 ME 462 Capstone Design Sponsor: Remy International Inc. IUPUI Design Team #1 Proposal Presentation May 3 rd 2007 Matt Schonauer Ibraheem Nezamuddin Martha Tadesse Brandon Harville Nathanial Greene Starter Drive Over Stress Fixture Design

2. 2 Overview Reason For Design Design Requirements Design Concepts Finite Element Analysis Design Evaluation Summary

3. Reason For Design Provided By: Remy International Incorporated.

4. Customer Requirements Versatility Adjustability Strength: Withstand large amounts of force Longevity Cost Effectiveness Design Requirements Engineering 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

5. 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*

6. 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.

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

8. 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.

9. Hexagonal Chuck Figure 3: Hexagonal Chuck.

10. 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.

11. Adjustable Pin Grip Figure 4: Adjustable Pin Grip.

12. 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.

13. The Base Of The System Figure 5: Vice Base

14. 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.

15. Bending Moment Assembly Figure 6: Bending Moment Assembly

16. 16 Finite Element Analysis

20. Design Evaluation Engineering Targets CompetitionOur PartsDelighted/Disgusted Criteria Versatility: Works with existing part line NoYesYes / No Adjustability: Able to test different size starter drive trains NoYesYes / No Strength: Long time before damage occurs 53 C Rockwell 60C Rockwell60C Rockwell / 30C Rockwell High material toughness7,000 ft-lb10,000 ft-lb10,000ft-lb / 5,000ft-lb Longevity: Corrosion resistant (black oxide sprayed) Yes Yes / No Cost Effectiveness: Low number of parts used 400 / 5 Use existing power supply NoYesYes / No Figure 7: Engineering Targets Evaluation.

21. 21 Summary Overview Reason For Design Design Requirements Design Concepts Finite Element Analysis Design Evaluation

22. Questions?