Numerical Analysis and Fabrication of Battery Holder for Two  Wheelers

Sabarinathan V.; Vivek Ram R.; Chethan K. N.; Mahesh G. T.

Authors

Sabarinathan V. Department of Aeronautical & Automobile Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal- 576104, Karnataka, India
Vivek Ram R. Department of New Product Development, Precitek Components Private Limited, Kanchipuram, Tamilnadu, India
Chethan K. N. Department of Aeronautical & Automobile Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal- 576104, Karnataka, India
Mahesh G. T. Department of New Product Development, Precitek Components Private Limited, Kanchipuram, Tamilnadu, India

Keywords:

Plastic materials, Injection moulding, Conversion of metal to plastic, ASA Material

Abstract

The high-performance plastics usage is increasing in the automobile field because of its advantages over other metals and alloys. Corrosion resistance, light weight, low cost, flexibility in design are the major advantages of plastics above the conventional metallic materials. In this paper a metal version component converted into plastic version in order to increase efficiency, reduce the overall cost of a two-wheeler and to improve the production rate of component. Different types of material such as PP + 15% TALC, PP + 30% GF, PP + 30% TALC, Nylon 6 + 15% GF, Nylon 66 UF, Nylon 6 UF, Nylon 66 + 30% GF, ASA LI941 and ASA LI913 tested for 10,000km road test, vibration test and fitment test. An injection moulding used to produce the component and ‘Mouldx3D’ software was used for mould flow analysis and other simulation. The different parts of injection moulding tool made up of C45, P20 and D2 materials. Among different materials, ASA LI913 was selected since it has better weather resistance than others and the impact strength matched to metal version component. Finally, it was found that the cost of the component made of Plastic considerably less than same component made of metal.