CAE ASSIGNNTBYB0910027_JITHIN

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COMPUTER AIDED ENGINEERING

ASSIGNMENT

Centre Name: Automotive Design and Engineering

Course Name:M.Sc (Engg) in Automotive Product Design

MANAGEMENT

PROGRAMM

E(PEMP)


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M

M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)

Declaration Sheet

Student Name Jithin Raj.R.P

Reg. No BYB0910027

Course Msc.(Engg) in APD Batch FT-2010

Module Code AME 501

Module Title Computer Aided Engineering

Module Start Date 02-11-2010 Submission Date 07-11-2010

Module Leader Mr.Umesh.S

Submission Arrangements

This assignment must be submitted to Academic Records Office (ARO) by the submission date before 1730

hours for both Full-Time and Part-Time students.

Extension requests

Extensions can only be granted by the Head of the Department / Course Manager. Extensions granted by any

other person will not be accepted and hence the assignment will incur a penalty. A copy of the extension

approval must be attached to the assignment submitted.

Late submission Penalties

Unless you have submitted proof of Mitigating Circumstances or have been granted an extension the penalties


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Attendance Details Theory Laboratory Fine Paid(if any for shortage of attendance)

Remarks

Assignment Marks-Sheet (Assessor to Fill)

Part a b c d e f Total Remarks

A

B

C

Marks Scored for 100 Marks Scored out of 50

Result PASS FAIL

Written Examination Marks Sheet (Assessor to Fill)

Q. No a b c d Total Remarks

1

M. S. Ramaiah School of Advanced StudiesPostgraduate Engineering and Management Programme- Coventry University (UK)

Assessment Sheet

Department Automotive Design and Engineering

Course Msc (Engg) in APD Batch Full-Time 2010

Module Code AME501 Module Title Computer Aided Engineering

Module Leader Mr.Umesh .SModule CompletionDate

30-11-2010

Student Name Jithin Raj.R.P ID Number BYB0910027


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)Abstract

In this era of globalization, the Industries demand faster, accurate, efficient and

effective ways to design, develop, manufacture a product and sell in the market. The

intervention of computers in the field of product development has played a key role in the

technological developments and new trends such as CAD /CAM/CAE. A detailed discussion

is carried on the field of Reverse engineering in 1st chapter. The various digitizing techniques,

current trend in reverse engineering, its legal compliances are also discussed in brief.

The 3D modelling and other applications in CAD soft wares play s a major role in

the balanced integration of CAD/CAM which combines to form CIM in Product Lifecycle

Management. In 2nd chapter, the basic construction in of a centrifugal clutch is studied and its

3D modelling, Assembly and related activities including clash analysis are done by using

CATIA V5 software package. The procedure followed for each process is discussed in brief

with appropriate pictures. The 2D drawings are generated in drafting workbench.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)Table of Contents

Abstract ....................................................................................................................................... i

Table of Contents ....................................................................................................................... ii

List of Figures ............................................................................................................................ v

List of Table ............................................................................................................................. vii

Nomenclature ......................................................................................................................... viii

Introduction to CAE ................................................................................................................... 1

CHAPTER 1 .............................................................................................................................. 2

1. 1 Introduction:................................................................................................................................. 2

1. 2 Role of Reverse engineering in PDC [1]: ...................................................................................... 2

1.3 The Current trend in Reverse engineering and its effects. ............................................................ 2

1.3.1 Digitizing techniques in Reverse Engineering[2]. ................................................................... 3

1.3.2 Surface Generation techniques [6]: .......................................................................................... 3

1.3.3 Legality and patent rights issue in RE: .................................................................................. 4

1 3 4 Ad t d di d t f RE 4


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2.2.11 Facing:................................................................................................................................ 12

2.2.12 Shoe lining: ........................................................................................................................ 13

2.2.13 Shoe: .................................................................................................................................. 13

2.2.14 Control leaf spring: ............................................................................................................ 14

2.2.15 Key:................................................................................................................................... 14

2.2.16 Cover plate: ........................................................................................................................ 15

2.2.17 Brass Screw:....................................................................................................................... 15

2. 3 Assembly of Centrifugal Clutch. ............................................................................................... 16

2.3.1 Exploded view of Centrifugal clutch: .................................................................................. 16

2.3.2 Assembly procedure:............................................................................................................ 17

2.4 Clash Analysis. ........................................................................................................................... 18

2.4.1 Observations: ....................................................................................................................... 19

2.4.1 Clash between Arm and Shoe .............................................................................................. 20

2.4.2 Clash between Shoe and Control leaf spring. ...................................................................... 20


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)APPENDIX A ....................................................................................................................... 32

Drawings of Centrifugal Clutch:....................................................................................................... 32

APPENDIX B ....................................................................................................................... 33

Drawings of Head lamp fairing:........................................................................................................ 33


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)List of Figures

Figure 2. 1 Centrifugal clutch[2] .............................................................................................................. 5

Figure 2. 2 Shank.................................................................................................................................... 6

Figure 2. 3 Bush Bearing -1 .................................................................................................................... 7

Figure 2. 4 Pulley .................................................................................................................................... 7

Figure 2. 5 Bush Bearing No.2 ............................................................................................................... 8

Figure 2. 6 Spider hub............................................................................................................................. 9

Figure 2. 7 ............................................................................................................................................... 9

Figure 2. 8 Hexagonal Screw............................................................................................................... 10

Figure 2. 9 Oil thrower ring .................................................................................................................. 11

Figure 2. 10 Arm................................................................................................................................... 11

Figure 2. 11 Special bolt ....................................................................................................................... 12

Figure 2. 12 Facing ............................................................................................................................... 12

Figure 2. 13 Shoe lining........................................................................................................................ 13


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)Figure 3. 1 Given Wireframe model in IGES format............................................................................ 23

Figure 3. 2 50% Surface modelling stage ............................................................................................. 23

Figure 3. 3 100% finished surface model ............................................................................................. 24

Figure 3. 4 3D Model after applying material ..................................................................................... 25

Figure 3. 5 Final rendered model of Headlamp fairing........................................................................ 26

Figure 3. 6 Result of Surface curvature Analysis. ................................................................................ 27


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)List of Table

Table 1. 1 Merits and demerits of RE ..................................................................................................... 4


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)Nomenclature

List of Symbols

Subscript

Acronyms

CAE Computer Aided Engineering

CNC Computerized Numerical Control

CAD Computer Aided Design

CAM Computer Aided Manufacturing

IGES Initial Graphic Exchange Specification.

NURBS Non Uniform Rational B-Spline Surface

PDC Product Development Cycle

RE Reverse Engineering


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)Introduction to CAE

The Introduction of CAE in an enterprise plays a major role in its developments .The

implementation of Computer technology in the industry has simplified the product

development processes in all the disciplines.CAE stands for Computer Aided Engineering

which consists of its branches as CAD, CAM etc. Computer Aided Design and

Manufacturing is the application of Computers and graphics software's to enhance the pace in

product development and manufacturing sector. CAD is a powerful tool in the field of

mechanical design and geometric modeling of products and components. The usage of CAD

gives the following advantages.

It Increases the productivity It improves the quality of design Standardization of design It helps to create a stable and reliable manufacturing data base. Error proof designs

CA i l h i i f C f l i i i


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CHAPTER 1

1. 1 Introduction:

In today's highly competitive global market, the product development enterprises are

constantly seeking innovative methods to cut down the lead time for new product

development to meet the customer expectations in all the aspects. Reverse engineering is a

process of duplicating an existing product, part, subassembly or a system without having its

drawings documents or any computer models. RE is a technology that supports an enterprise

to shorten its product development cycle.

1. 2 Role of Reverse engineering in PDC[3]

:

Reverse engineering is being used as an innovation strategy through which anorganization can develop a product by analyzing and benchmarking thecharacteristics of a similar product which is already developed by a competitor.

Reverse engineering applications are widely used in various fields such as

Automotive, Aerospace, Software engineering, Consumer products, Jewellery

design etc.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)which consume long time for a product to get launched in the market. The introduction of

reverse engineering in the industry has lead to lower the demand of highly qualified andskilled professionals as the RE process has simplified the whole process. At the same time,

the opportunity in the field of surface modelling and digitizing are increasing as well.

1.3.1 Digitizing techniques in Reverse Engineering[3]

.

The RE process is generally subdivided in to three processes. They are, Data

capturing, Pre-processing and CAD modeling. The data of geometric shape of the a physical

model is acquired by using data capturing techniques. The captured data is usually

represented as 3D data points,2D slices or images. The captured data needs to be manipulated

to facilitate surface modeling. The irregularities on the captured surface which are termed as

'Noises' need to be cleared by data cleaning. The digitizing techniques in RE are basically

classified in to two types. They are, Contact type and non contact type methods.

Mechanical contact digitizing by CMM [5],[6]: CMM stands for CoordinateMeasuring Machine. CMM is equipped with a touch trigger probe which senses

the surface of the part when it touches the surface. As the measurement of

dimensions is from point to point, the measuring efficiency is very low in case of

l 3D f


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)the model. The reconstruction of surfaces is necessary to provide a suitable CAD model for

manufacturing or simulations such as Computational fluid dynamics or Finite ElementAnalysis. Rapid surfacing (RS), Classic surfacing (CS) and Hybrid Surfacing are the two

main tools used in Reverse engineering to reconstruct the external surfaces from complex 3D

shapes. RS is a fast process compared to CS. In Rapid surface technique the surface is formed

by a three or four sided patch. Classic surfacing is a manual procedure of creating surfaces.

Hybrid method is a combination of both Rapid and classic methods.

1.3.3 Legality and patent rights issue in RE[1]:

In most of the applications, Reverse engineering is considered as the viable

technology for product development. However there are legal and ethical limitations that

must be considered. Reverse engineering is a common procedure that typically involves

disassembly, examination and analysis of a product to reveal its design and function.

Normally this is done for competitive analysis and sometimes for building a new product

with similar features. It is legally and ethically acceptable for a company to purchase a

commercially available product to analyze design and develop a similar product or to follow

the manufacturing procedure, provided the new product and methods do not violate the patent

i h f h Th b i l li i i d i h i i


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CHAPTER 2

2.1 Introduction: CENTRIFUGAL CLUTCH

Centrifugal clutch uses centrifugal force to engage and disengage the Engine drive

from the final drive. These types of clutches are commonly used in mopeds and mini bikes

for speed transmission. Centrifugal clutch transmits torque as a function of driving speed.

The clutch of shoes or friction pads is connected with a coil spring or leaf spring. The shoes

assembly in which the shoes are equally distributed is mounted on to a carrier rim. The

carrier rim is mounted on to a spider hub and the driving shaft which links the engine drive to

the clutch assembly is mounted is keyed on the spider hub.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2. 2 3D CAD modeling of centrifugal clutch using CATIA.

The CATIA is the most widely used CAD package in the industries across the globe.

CATIA supports an enterprise in every aspects of its product development cycle .In this

chapter, CATIA is used to develop the Solid models, 2D drawings, to carry out the Assembly

and clash analysis of the parts of centrifugal clutch Assembly. This could help to explore the

software to an extreme depth and got an opportunity to have an exposure to industrial design

standards. Also, it could give a clear idea of the functioning of a centrifugal clutch. The 3D

modelling and drafting is not done for the standard parts. The procedure followed to develop

the 3D models for all the elements except the standard parts are discussed below. The

standard parts are directly exported from 'Catalogue browser'.

2.2.1 Shaft:


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2.2.2 Bush Bearing -1:

Figure 2. 3 Bush Bearing -1

CAD modelling procedure:

The external diameters of the bush are created by SHAFT and internal diameter byPOCKET operation.

h dii id d b i G i


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CAD modelling procedure:

The outer body and the internal undercut are created by using SHAFT option. The POCKET option is used to create the shell shape. The radii at the required area are created by using EDGE FILLET option. The 3 holes at 45 are created by using SLOT options with reference to a circle

drawn on the adjacent surface. The distribution along the circumference is done by

CIRCULAR PATTERN. The Hole inside the undercut is created by using HOLE option.

2.2.4 Bush Bearing -2:


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2.2.5 Spider Hub:

Figure 2. 6 Spider hub


The external diameters and steps of the bush are created by PAD option and internal


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The external body is created by PAD operation. The Internal pocket is created by using SHELL option. The radius at the required area is provided by using EDGE FILLET. POCKET option is used to create slots on the outer diameter. The distribution of the slots is done by using CIRCLUAR PATTERN. 10.2 holes at the circumference are created by developing an addition plane at 45. The same holes are distributed along the body by using CIRCULAR PATTERN.

2.2.7 Hexagonal screw M10x 25:


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2.2.8 Oil thrower ring:

Figure 2. 9 Oil thrower ring


The cross section of the part is created by using SHAFT operation.


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The PAD operation is used to create the cross section of the part. The angular slots are made by using POCKET operation. The holes along the slot are created by using POCKET operation.

2.2.10 Special Bolt:

Figure 2. 11 Special bolt

CA i


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The cross section is made by using PAD operation. Two holes along the surface are created by using HOLE option. The radius on the edge is created by using EDGE FILLET option.

2.2.12 Shoe lining:

Figure 2. 13 Shoe lining



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The radial profile is created by sketching and extruded by using PAD operation POCKET tool is used to cut down the collar. The rectangular pocket along the curvature is created by sketching on to an additional

plane and by using POCKET tool.

The thread on the outer surface is created by using HOLE option and distributed tothe required positions by using RECTANGULAR and CIRCULAR PATTERNS

The Circular protrusion at the centre is done by PAD tool and then threaded hole isdone

2.2.14 Control leaf spring:


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The cross section including the radius is created by sketching end extruded to therequired thickness by using PAD tool.

2.2.16 Cover plate:

Figure 2. 17 Cover plate



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The screw geometry is developed by sketching on a plane and SHAFT tool. Then the thread is given by using THREAD option. The chamfer at the thread entry area is provided by using CHAMFER tool.

2. 3 Assembly of Centrifugal Clutch.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP) The part-Pulley is imported to the Assembly workbench by using EXISTING

COMPONENT tool. i.e., Bottom-Up method is used to complete the assembly.

Then the part is constrained as the base part using FIX tool. Parts which are adjacent with the Pulley are assembled by using the EXISTING

COMPONENT tool and constrained to its required positions by relevant constraint

tools available.

Other parts were made as a separate Sub-Assembly in a different Assemblyworkbench and then exported to the Main Assembly and following Constraint tools

were used to restrict its degrees of freedom.

Coincidence Constraints: This tool is used to align the major axis of eachpart to its base part. This can also be used to align the axis of holes, or align

the planes edges or faces.

Contact Constraints: Contact constraints are used to create surface contactbetween two different parts so that both parts mate each other.

Offset Constraints: This tool is used to maintain a defined distance betweentwo surface and edges of different parts. This can also be used to maintain

parallelism between the faces of different parts.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2.4.1 Observations:

Majority of the clashes are observed between nuts and bolts which can beignored.

The option used for clash analysis is Contact +clash option.74 clashes areobserved among 227 interferences.

Out of 74 clashes, the major 5 reports are shown below the Clash Analysisreport.


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Figure 2. 21 Clash Analysis Report

2.4.2 Clash between Arm and Shoe

Figure 2. 22 Clash between Arm and Shoe

The cash is due to the angle difference between the ARM and SHOE. Thedimensions are maintained as per the GIVEN 2D drawing.

2.4.3 Clash between Shoe and Control leaf spring.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2.4.4 Clash between Shoe and Carrier Rim.

Figure 2. 24 Clash between Shoe and carrier rim

0.28 mm clash is observed between Shoe and carrier rim. The dimensions ofthe elements are maintained as per the given drawing.

2.4.5 Clash between Shoe and nut.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CHAPTER 3

3.1 Introduction.

The enormous developments in the field of Product design and CAD/CAM has lead to

remarkable changes in the design development technologies too. In Automobile sector, the

aesthetical and ergonomic appeal of a car has become one of the major factors for the

successful launch of a car in the market. Earlier, Geometric modeling and wireframe

techniques were used to create complex structures. But it had its own limitations. The

complex shapes design and representation of Automobiles, Aircraft bodies and ship structures

could not be achieved by using these techniques. By the development of surface modeling

techniques, the possibilities in the field of product designing got emerged to an extreme level.

Surface modeling is used in CAD to represent the skin of a 3D element which cannot be

represented through a 2D drawing. Such surfaces don't have any stable dimensions as

available for cylinder, planes or conic structures. The major application of free form

surfacing comes in designing of Automobiles, Aerospace, turbine blades, consumer products

and all other engineering design applications. The super cars and sport utility vehicles highly

aerodynamic shape for the body and this can be designed only by the use of surface modeling


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Figure 3. 1 Given Wireframe model in IGES format

By studying the geometry and the features of the given model, somediscontinuous curves and extra lines are detected and deleted as required.

As the profiles are symmetrical on both sides, except the instrument panel


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The major tools used for Surface modelling are FILL, MULTI SECTION andBLEND.

MULTI SECTION tool is used in the area where 4 curves form a surface. andthe TANGECY is maintained with the adjacent surface.

SPLIT and JOIN tools are used to solve the issue with the broken lines andcontinuous lines

Once the surfacing at one half of the plane and the instrument panel area gotfinished, the symmetrical portions are mirrored to the corresponding plane.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)3.3 Application of Additional features and rendering:

After completing all the surface geometries, appropriate material was appliedon to the model by using APPLY MATERIAL tool.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP) After applying the material properties, to enhance the visual characteristics of

the model, the rendering was done by attaching the image of the headlamp on

to a bike's image. PHOTO EASY STUDIO TOOLS was used to do the final

rendering. The material property was changed in to red colour in the final

rendered image in order to match the colour with the image of the bike.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP) The surface to be analyzed is selected which highlights various colors on the

surface according to the severity of the irregularity. The color range s from

Green to Red. The green stands for Good surface and Red stands for Non

uniform or irregular surface.

The result is as shown in the picture given below.

Figure 3. 6 Result of Surface curvature Analysis.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CHAPTER-4

4.1 Comments on learning outcome.

The pace of technological developments is very high in the field of Product

development sector. Thus the industries are taking enormous efforts to update their

technological capacity to get hold in the market. At the same time, it is mandatory for a

design engineer to update the skills and knowledge according to the latest technologies. This

module was very much helpful to attain the knowledge about the modern technological trends

in the field of design and engineering, CAD CAM/CAE and its integration and role in the

field of PLM. A variety of its applications and the theoretical aspects were studies in brief.

Though a basic knowledge on the engineering graphics was already there, the relevant

sessions could give a clear idea on its applications in the industry. A clear understanding on

the new product development, the role of CAE in it and the functions of different islands of

Automations which comprises the CIM is also achieved. The Lab sessions on CATIA

software has helped to gain a vast knowledge on different applications of the software

package and the functions of different tools according to the requirement. The practical

demonstrations on Reverse engineering and Rapid prototyping were also very helpful. The


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)to improve the appearance. Then the surface curvature analysis was done to

verify the quality of surface being created. The procedure followed for each

process is mentioned briefly in each chapter.

The conclusion of the above study is that the computerization of product design and

development process could simplify the entire process and could help the industry to cut

down the total lead time required for the product development.


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)REFERENCES

[Referring Web Published Article]

[1] Unknown Article, Legal Ethics and Patent infringement, http://www.onlineethics.org,Retrieved on 29-11-2010

[Referring Web Published Article from which photographs are extracted]

[2] Unknown, Photo of Centrifugal clutch, www.directindustry.com, Retrieved on 28-11-2010


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BIBILIOGRAPHY

[Referring Web Published Article]

[3] Fahraz Ali,B.V Chowdary,C.A.C Imbert Part dsign and evaluation through reverseengineering aproach, www.ijme.us, Retrieved on 18th Nov. 2010

[4] Patri.KVenuVinod,Rapidprotyping,Laserbasedandothertechnologieshttp://books.google.co.in, Retrieved on 18th Nov. 2010

[5] A.W.L Yao,Application of 3D scanning and reverse engineeringtechniques,http://www.springerlink.com ,Retrieved on 28-11-2010

[6] Unknown,Product Info,http://www.boulderinnovators.com ,Retrieved on 28-11-2010[7] Unknown Author,Laser scanning techniques,www.rob.cs.tu-bs.de , Retrieved on 28-11-2010[8] G M Lekrivance,I Kennedy, Hybrid surface reconstruction techniques for

Automobiles.http://www.engineeringletters.com, Retrieved on 28-11-2010


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)APPENDIX A

Drawings of Centrifugal Clutch:

Appendix-A contains 14 A-4 size drawings and 2 A-3 size Assembly drawings of

Centrifugal clutch including Bill of Material


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)APPENDIX B

Drawings of Head lamp fairing:

Appendix-B contains 1 A-3 size drawings OF Headlamp fairing of Motor bike with

different views and the major dimensions.


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