Development and Characterization of a Remanufactured Motorcycle Clutch Hub from End-of-Life Aluminium Alloy
DOI:
https://doi.org/10.70112/arme-2024.13.1.4238Keywords:
Reverse Engineering, End-Of-Life (EOL) Aluminium Alloy, Transient Thermal Analysis, Fourier Transform Infrared (FTIR) Spectroscopy, Fatigue FailureAbstract
This study aims to employ reverse engineering in the development of the Yamaha CY 80 motorcycle clutch hub using end-of-life (EOL) aluminium alloy obtained from automotive vehicle scraps. The remanufactured motorcycle clutch hub underwent characterization and transient thermal analysis by integrating the geometric and structural features of the clutch hub. The EOL aluminium was thoroughly washed with a sodium hydroxide (NaOH) solution, cleaned with running water, and dried under sunlight to remove impurities trapped on the metal surfaces. The EOL aluminium alloy was melted in a gas furnace, and the molten metal was cast into the clutch hub using a permanent mold designed with the geometric features and characteristics of the Yamaha CY 80 motorcycle clutch hub. The EOL aluminium alloy was characterized using Fourier transform infrared (FTIR) spectroscopy and scanning electron microscopy-energy dispersive spectroscopy (SEM-EDS). The remanufactured CAD model of the Yamaha CY 80 motorcycle clutch hub was subjected to transient thermal analysis using ANSYS Workbench to predict the thermal behavior of the clutch hub during operation. The FTIR spectra exhibited the following distinctive bands: Al-O stretching modes in octahedral and tetrahedral structures, as well as symmetric bending of Al-O-H, with wavenumbers between 340 and 3131 cm-1 for -OH bonds and between 2109 and 1688 cm-1 for H-O-H bonds. The SEM-EDS micrographs indicated that the two main elements were bromine and silicon. Results from the transient thermal analysis indicated that the minimum and maximum temperatures were 40.109 °C and 250.09 °C within a time frame of 240 seconds. The maximum total heat flux was 30,271,000 W/m2. The compressive yield strength and tensile yield strength obtained in this study were 280 MPa, while the ultimate tensile strength was measured at 310 MPa. The alternating stress levels ranged from 62.05 MPa to 275.8 MPa. This study established that the material is susceptible to fatigue failure, as the alternating stress levels were below the material’s yield strength of 280 MPa.
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