Manufactura de catalinas para motocicletas caso de producción en el Ecuador

摘要

In this project, the feasibility of producing motorcycle sprockets in Ecuador is analyzed. The engineering design of the sprocket concerning the CAD, manufacture and heat treatment for this part is also discussed. Conclusions are made about the cost analysis for this project.The procedure to model the sprocket using a computer aid design CAD software, is explained. After that, 12 procedures to manufacture sprockets are analyzed considering their local applicability. Three different types of raw materials are considered. These may be steel rods of different diameters and lengths, or a hot rolled steel plate. Then, the different cutting methods like plasma, laser, water jet cutting and punch pressing are analyzed. The teeth of the sprocket may be machined by cutting tools like: the gear hobbing machine, mechanical milling machine and CNC milling machine; or by laser cutting. Afterwards, the sprocket's teeth must be heat treated by induction heating and followed by quenching. Finally the sprockets need to be galvanized and packed for sale.For the cost analysis, updated quotations of machines and raw materials are obtained. Also, operational costs and production capacity is discussed. The final cost of the 12 manufacturing options in the year 0th are obtained to choose from them the top 4 options with the lowest unit cost. Production, sales, machinery costs, labor, input resources and expenses of these 4 methods are projected to 5 years to select the method that provides the most competitive price in the market.From all the manufacture methods studied in this work two are considered the most appropriated, based in the results of the cost analysis:1) The one that uses 8 mm steel plates as raw material, laser cutting for the teeth and all internal holes, quenched after induction heating at 500 KW at 100 Hz for 28 seconds, quenched in water and galvanized; is the most appropriate method.2) The second most feasible method is the one that uses the same raw material but uses a punch press to blank the discs from the plate, a plasma CNC cutting machine to cut the inside holes, a hobbing machine for the sprocket's teeth, a tapping machine to drill the 4 bolt holes and the same quenching and galvanizing procedures named before.In the cost analysis the 4 most suitable manufacturing options are discussed in details. It was found that the project is economically attractive considering a MARR of 5.5%. Considering an optimistic, realistic and pessimist scenery the manufacturing processes from most favorable to the least favorable processes are 10, 12, 8 and 9.