Reverse Engineering of Yamaha CY80 Clutch Basket using 7075 Aluminum Alloy for Component Functional Requirement

Abstract

The CY 80 clutch basket is a bowl-shaped gear- driven housing bolted onto the end of the clutch shaft and functions as the cover for clutch components assembly. The functional requirement of this part requires high strength and wear resistance characteristics. This research work focuses on the design and development of permanent mould for the production of CY 80 clutch basket using 7075 Aluminum alloy. The CY 80 clutch basket was designed using Creo Element software and manufactured by gravitational casting process using a crucible furnace. Virtual simulation of the produced component shows that the design is safe. Material analysis and further test performed by running Cy80 motorcycle engine that is coupled with the clutch basket shows that the manufactured CY 80 clutch basket performs its intended function.