Design Improvement of Existing Slip-on Sprocket

The sprocket is a very vital component in the transmission of power and motion in most motorcycle; there is always a pair (rear and front) in a motorcycle. The front sprocket drives the rear sprocket via chain connection. They exist in various dimensions, teeth number and are made of different materials. This project studies involve the fundamentals of slip-on sprocket design and manufacturing of the product to be slipped onto the most types of the motorcycle rear sprocket which require a novel torque booster through reverse engineering approach. It discusses analysis, dimensioning, drafting and drawing, prototype printing, chemical composition, material selection, choice of manufacturing process, heat treatment, and surface finish as the nine steps that need to be followed sequentially in this reverse engineering approach. In this work, design fro manufacturing (DFM) analysis had proven that 1 mold designation will produce a 10 outer teeth and 9 inner teeth slot per section. The dimensions information had been extracted by using Coordinate Measuring Machine for greater accuracy. This slip-on sprocket product also proven can be assembled into most types of motorcycle sprocket make from the production of the three dimensional (3D) prototype made of ceramic powder. The mold and die preparation methods are used to produce the slip-on sprocket from the blanked medium with the major chemical composition of Fe=86.3%, Al=8.22%, P=2.79%, and Ca=1.15% which analyzed by the X-ray Fluorescence Machine.