Analysis of Optimal Manufacturing Method for Discrete Parts with Thin Sections

By
Wan Muhammad Noraiman
17926

Bachelor of Engineering (Hons) (Mechanical)

September 2016

University Teknologi PETRONAS

32610 Bandar Seri Iskandar
Perak Darul Ridzuan.

TABLE OF CONTENTS
Chapter 1: Introduction
1.1 Project background

1.2 Problem Statements

3- 4

1.3 Objectives

1.4 Scopes of Study

5
Chapter 2: : Literature Review

2.1 Introduction to Manufacturing

2.2 Type of Manufacturing Processes Details

67

& Relevancy to the Project

2.3 List of Available Given Companies

2.4 Comparisons on Strength & Weaknesses

of Each Company
Chapter 3: Methodology
3.1 Flowchart

10

3.2 Gantt Chart

11
Chapter 4: Conclusion and Recommendation

4.1 Conclusion

12

4.2 Recommendation

12
References

References

13

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Chapter 1: Introduction
1.1 Project Background
The Slip on Sprocket project produced by the earlier students was considered a great
innovation in improving the mobility and the torque of the vehicle without the need of the
complicated traditional assemblies. However the project being done by the earlier students
involved expensive and uneconomical methods of producing the Slip on Sprocket that was made
in the previous projects.
This project assigned objective is to reduce the cost of the production of the Slip on
Sprocket. The cost of the production is needed to be reduced so that the cost of each Slip on
Sprocket being sold in the market meets the consumer level of expectations especially since the
original main aim of this project is to reduce the cost needed to improve the vehicles
performance.
By the end of this project, the result will be expected to have the production cost of the
Slip on Sprocket without compromising the final result of the improvements being achieved in
the results from the previous projects being done by earlier students.
This project will involve a lot of researches involving the best manufacturing methods in
terms of performance and cost and preventing any unnecessary significant impacts on the final
products final performance.

The image shows the 8-part

Slip on Sprocket developed
and manufactured by the
previous students in
previous projects.

The image shows an

example image of 3D Metal
Printing used by the
previous students which is
effective but very costly.

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The image shows the

reference sprocket (Honda
EX5 Standard Sprocket) for
making the 8 part Slip-onSprocket.

1.2 Problem Statement

The Slip on Sprocket device is used to increase performance of the vehicle involved and also
to reduce the excessive cost of replacing the entire sprocket and the work needed to apply the
device onto the vehicle. However the current manufacturing process being used by the previous
students in their projects are only practical for producing individual single products at a time and
uneconomical for the consumer market which is in need of mass production.
The problems in the current manufacturing method (3D Metal Printing) can be simplified as
the following:
1. The current manufacturing method which is 3D Metal Printing which is currently made
in Kuantan region is very expensive where the cost of each Slip on Sprocket produced
can be up to RM2500 per set.
2. The 3D Metal Printing method is not suitable for mass production mode as its production
speed does not meet the necessary amount of product produced at a certain amount of
time which can lead to hiking in price.
3. The 3D Metal Printing method involves a lot of pre-complete materials and needed to be
supervised despite the accuracy of the product produced. This can lead to more labor cost
which indirectly increases the cost of end product.
4. The raw material used for the powder for the 3D Metal Printing is also very
expensive, meaning, the price is very hard to be reduced since the first part of the
manufacturing sub-process is already expensive.
The following table shows the rough but wide aspects of differences of data between the
standardized OEM Sprocket being produced in the market vs the Slip on Sprocket being
produced currently (3D Metal Printing).

(Full Table in the Next Page)

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Type of Data
Size
Density
Material

OEM Sprockets
168.9862 mm~
8000 kg/m3
Type:
Medium Carbon Steel

Slip on Sprockets
168 170 mm (Strapped).
8500 kg/m3
Type:
Cobalt Chromium

Composition:
Carbon, C: 0.45%
Manganese, Mn: 0.5%
Phosphorus, P:0.03% Max
Sulfur, S: 0.04%

Composition:
Chromium, Cr: 28.5%
Molybdenum, Mo: 6%
Nickel, Ni: 0.25%
Iron, Fe: 0.2%
Carbon, C: 0.22%
Silicone, Si: 0.7%
Manganese, Mn: 0.5%
Tungsten, W: 0.01%
Phosphorus, P: 0.01%
Sulphur, S: 0.005%
Nitrogen, N: 0.15%
Aluminium, Al: 0.05%
Titanium, Ti: 0.01%
Bor, B: 0.006%
Cobalt, Co: Balance %
0.29
220 230 Gpa
600 Mpa 800 Mpa
500 Mpa 840 Mpa
270 310 HB
96%
5 minutes
RM2,500 per Slip on Sprocket
(3D Metal Printing)
3D Metal Printing
48 50 N.m. @ 1491.9 RPM

Poissons Ratio
Elastic Modulus
Tensile Strength
Yield Strength
Hardness
Performance
Assembly Time Required
Cost

0.28
205 GPa
580 Mpa
500 Mpa
170 HB
100%
25 minutes
Rm14.80 per sprocket.

Manufacturing Technique
Torque produced, N.m.

Investment Casting
50 52 N.m. @ 1491.9 RPM

From the table shown above, we can see that the 3D Metal Printing is much more
expensive than the method currently being used in the market which is already involving
producing full sized sprockets. So, from this table, we can safely deduce that the current method
is not suitable for mass production and is not cost efficient. Therefore, other types of
manufacturing methods are needed to be investigated in order to produce the product in the
highest of quality but also the best in terms of cost efficiency.

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1.3 Objectives
1. To analyze the problem of the current manufacturing method of the Slip on Sprocket
system.
2. To improve the manufacturing cost efficiency of the product without compromising the
integrity of the structure.

1.4 Scopes of Study

The scopes of the study of this projects mostly involving researching, developing & finally
deciding the best manufacturing method for producing the product involved which is the Slip on
Sprocket. The best manufacturing method will be judged based on the following criteria:
1. Production Cost.
2. Production Rate.
3. Production Quality.
4. Production Materials.
Chapter 2: Literature review
2.1 Introduction to Manufacturing
Manufacturing is considered to be a very important global business around the world ever
since the start of the industrial revolution back in the 19th century and still maintain its
importance in todays world. This is simply because mass production manufacturing helps to
reduce the price of almost any product significantly while still virtually maintaining its end
product quality & help boost the economy significant than previous expensive processes used.

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2.2 Type of Manufacturing Processes Details & Relevancy to the Project

Manufacturing
Process
Casting
(Investment
Casting)

Forging

Machining

Summary

Advantages

Disadvantages

Relevancy/Suitability to
Project
Casting is a manufacturing Casting is usually the most Casting can produce (low Casting is the most
process where the molten
preferable method of
risk) defects such as gas
suitable manufacturing
material such as metal,
manufacturing for
porosity, shrinkage
method to be used in
plastic, etc. are poured into obtaining a balance of
defects, mold material
almost any mass
molds containing desirable rigidity and manufacturing defects, pouring metal
production system that
shapes where the mold can convenience while
defects, and metallurgical involves complex designs
be temporary (sand mold), maintaining the high rate
defects. Need a complete
like the Slip on Sprocket.
or permanent mold (metal of production in factories. mold beforehand with the The type of casting
mold).
desired shape before
currently favored is
starting process.
investment casting.
Forging is a
Forging is the highest
Forging is also the most
Forging is also like casting
manufacturing process
quality of the
expensive manufacturing
with in need of die that
where a solid material is
manufacturing process,
process of all despite of its have the desirable shape to
shaped by using
where the chance of
quality. Therefore it is
produce and to be worse
compression usually done getting defects are
usually only used for
much more expensive than
by using die. It can be
relatively low, and always products that really in
casting process. Not
done by hot forging or
produce the highest quality need of the forging end
economically suitable for
cold forging.
results.
quality.
making first few designs.
Machining is a
Machining especially
Machining, although as
Machining can be
manufacturing process
CNC machining are very
expensive as the forging
considered to be used in
where a solid piece of
precise where the offset of process, but is still
this project for
material is cut out and
plus and minus of the
relatively expensive due to manufacturing the
machined according to the tolerable error is usually
the type of machine that
sprocket mentioned but
desired shape in a
the smallest among all of
required for the process
due to multiple projects
controlled manner.
the manufacturing
which is CNC machine or present from different kind
processes. This is very
Manual and the production of sources, the projects
good for super precise
size limit is relatively
relying on the machines
engineering mode.
small.
are prioritized.

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3D Printing
(Powder)

A manufacturing process
currently also being used
at Block 16-00-05 in UTP.
The machine prints
powder based materials
into fragile solid materials.
Using CATIA as the 3D
model source.

Metal Printing Metal Printing is a

manufacturing process
where a model is printed
using any metal powder
from a computer model.
The fragile powder printed
model is then heated and
infused in order to
strengthen it in order to
have metal properties.

Excellent for fabricating

prototypes at a very low
cost. Reduces the cost of
overall frequent 3d
printing for research
purposes.

The metal printing process

is very flexible and also
relatively cheap for patent
designing and
experimentations. It can
print very complex metal
shapes on par or even
better than castings where
the model is printed by
using computer instead of
using molds.

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Cannot be experimented
since the end product is
very fragile. The end
product could have defects
after applying the final
steps of bonding process
when applying the glue,
where the product may get
reduced in size and cause
difference from actual
product design diameter.
The metal printing is not
suitable for mass
production as it involves a
lot of labor which will
increase costs of the
products being
manufactured.

Suitable for this project as

the printing although has
some flaws, it is very
economical. Thus,
frequent printing will help
the students see and able to
research more clearly and
enhance the innovation
skills needed for this
project.
Metal printing is the most
suitable method for
previous project as it is
relatively cheap and it is
also more convenient and
faster to execute that other
type of manufacturing
process. Models can be
made through 3D Drawing
apps first before being
printed, effectively
reducing the defect risks
when printing.

2.3 List of Available Given Companies.

Company

Company is
Manufacturing
Sprocket

Shanli Agricultural
Engineering Sdn Bhd

Yes.

First Wave Technology S/B

Yes.

SunMarkGlobalSawMachine

Yes.

Shentuck Engineering Sdn

Bhd

Yes.

RS Coyne Trading Sdn Bhd

Yes

Ivan Mah

N/A

Motorcycles Holdings Sdn

Bhd

Yes

Kilang Rantai S. A. Sdn Bhd

Yes

Miss Gear Engineering and

Trading Sdn Bhd

Yes

Tan Lan Holdings (M) Sdn

Bhd

Yes

Information of the company

No further information besides in
the image given.
Yes, detailed information can be
found on
http://www.firstwave.com.my/
Yes, detailed information can be
found on
http://w213747.company.weiku.co
m/
Yes, detailed information can be
found on
http://www.shentuck.com/index.ht
ml
No further information besides in
the image given.
Not information available as well.
Not found in the internet.
Yes, detailed information can be
found on
http://www.mdh.com.my/
Yes, detailed information can be
found on
http://www.kilangsprocket.com/Gr
oup_Of_Companies.html
Same details as shown in the
image on
http://www.companiess.com/miss_
gear_engineering_and_trading_sdn
_bhd_info1732101.html
Yes, detailed information can be
found on http://www.tanlan.com/
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Main
Manufacturing
Method

Distance
from UTP

Contact No.

Working
Hours

N/A

(Kedah)
289 km

017- 469 7789

N/A

Casting

(Selangor)
199 km

03 - 6156 5999

0800 - 1800

N/A

(Sabah)
1678 km

60 169 - 4970

N/A

N/A

(Penang)
190 km

04 -332 5663, 331

7662, 331 7029

N/A

N/A

(Selangor)
220 km

012 - 209 1451

N/A

N/A

N/A

N/A

N/A

Manual
Machining

(Selangor)
225 km

03- 9223 3456

03 - 9223 4567

N/A

N/A

Penang
(166km)

04 - 390 7841

N/A

Machining

(Johor)
552 km

07 - 351 9346

N/A

N/A

(Perak)
38.2 km

05 - 466 1560

0800 - 1800

2.4 Comparisons on Strength & Weaknesses of Each Company

Company
Shanli Agricultural Engineering Sdn Bhd

First Wave Technology S/B

Strengths
No information was available besides the image given.
The company offers the method that we are currently considering
to execute which is casting. The information of the casting can be
found in the production & facilities section of the companys
website. Furthermore, it also provide the standard testing
services for checking the overall strength of the final
manufactured product such as the tensile strength. Finally, the
company also offers custom make sprocket in terms of shape and
materials.
No information was available.

SunMarkGlobalSawMachine

Shentuck Engineering Sdn Bhd

RS Coyne Trading Sdn Bhd
Ivan Mah

Motorcycles Holdings Sdn Bhd

Kilang Rantai S. A. Sdn Bhd

Miss Gear Engineering and Trading Sdn Bhd
Tan Lan Holdings (M) Sdn Bhd

The company provides custom make sprockets as can be seen

and found on the Sprocket Gear section under the Our Product
section.
No information was available besides the image given.
No information was available.
The company claimed that it is one of the largest manufacturer in
motorcycle sprockets for market OEM such as Honda & Yamaha.
Thus, the final quality of the product should be very satisfying as
the quality standard of the OEM sprockets are not easy to be met
with.

The company provides sprocket manufacturing but does not

provide any manufacturing details needed for further
analyzation.
No information was available besides the image given.
The company is currently located the nearest among the other
companies that are shown in the table, thus, this will help the
project to be executed better if the company provides
manufacturing for the sprockets involved in the project.

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Weaknesses
No information was available besides the image given.
No further information regarding the weaknesses of the
manufacturing method done by the company. Further questions
should be forwarded to the company in order to find out the
necessary details such as manufacturing cost and time.

The company does not provide the necessary information that is

relevant to the project involved. The only clue that the company
is somehow involved in manufacturing sprocket is the
manufacturing of sprocket rim.
The sprockets shown are mostly small in diameter and mostly
used for making the conveyor belts system in the manufacturing
markets. Thus, this company may not offer any sprocket
manufacturing.
No information was available besides the image given.
No information was available.
No information on the manufacturing method done by the
company was provided in the site. But based on the images
shown under the manufacturing section, it seems that the
company uses machining instead of casting. This may cause some
troubles in negotiating as the company has a high chance of using
pre-complete materials and only provide slight custom make for
the rear sprockets.
The company may not provide manufacturing other than the
standard OEM design currently used for the market which is full
size sprockets.
No information was available besides the image given.
The company may not produce and meet the requirements of the
final quality of the manufactured products for the project
sprocket as the company is only currently making sprockets
mainly for bicycle. Further investigation should be made.

Chapter 3: Methodology
4.1 Flowchart
The procedure usually involves researching about the available manufacturing methods
currently offered by the local companies. The other procedures involved in this project are
explained in the following flowchart as shown below:

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4.2 Gantt Chart

Final Year Project 1 Gantt chart.
Task

Selection of Project topic

Preliminary Research Work
Submission of Extended Proposal
Selection of the Best Manufacturing Method
List of Manufacturing Methods Available
Researches of the Methods listed.
Selection process based on elimination.
Selection process based on criteria.
End Product Calculations on the Method Selected
Proposal Defense
Company Searching Based on the Selected Manufacturing Method.
Submission of Interim Report

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Week
8 9

10

11

12

13

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Chapter 4: Conclusion & Recommendation

4.1 Conclusion
Based on the past researches made by the previous students, we can conclude that the result
of the Slip on Sprocket is very satisfying and can be implemented in the real life situations.
Hence, the main objective of this project is to take the properties of the successful Slip on
Sprocket and then make it possible to produce it in a mass production with significantly less cost
than the manufacturing method that is currently used by the previous projects.
This is so that, after the end product comes after the manufacturing process, the product is
not also cheaper than the product in the previous projects but also maintaining the integrity of the
end product so that its quality and purpose of usage will still be maintained. Not to mention, to
make the product very affordable than buying a whole new sprocket to increase the torque of the
vehicle, since this product is currently targeted for the low-income people in the need of
transporting heavy goods with their already owned vehicles.

4.2 Recommendation
Based on the scope of study above, this project is nor aimed to produce or improve the Slip
on Sprocket but to improve and select the best manufacturing method for the Slip on Sprocket
especially for mass production. Therefore, it is recommended to conduct researches and
investigations on multiple types of manufacturing process from multiple companies so that the
decision on selecting the manufacturing process is filtered out thoroughly in order to produce the
best decision.

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References:
1. Nurshafiq (2016), Analyze Performance of Torque Boosting Device, Universiti
Teknologi Petronas.
2. ASTM CoCr Alloy, Arcam EBM System, www.arcam.com.
3. Ebhota Williams S, Ademola Emmanuel, Oghenekaro Peter, Fundamentals of Sprocket
Design and Reverse Engineering of Rear Sprocket of a Yamaha CY80 Motorcycle,
International Journal of Engineering and Technology Volume 4 No. 4, April, 2014
4. Sprocket Materials, http://www.keystonemfg.com/sprocketmaterials.php.
5. Groover, Mikell, Fundamentals of Modern Manufacturing (4th Edition) (2010).

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