BIKE PARTS ASSEMBLY

There are three department in this company: –   

1. FABRICATION DEPARTMENT

1. FABRICATION

1. INTRODUCTION

Fabrication is the process of manipulating the raw material i.e. metals like steel to make structures, machines, etc. It is basically the process by which metal structures are made by cutting, welding, machining, bending and assembling. In fact, fabrication is an integral part of the manufacturing process.

TYPES OF FABRICATION PROCESSES

There are several kinds of fabrication processes, of which the most common are: cutting, folding, machining, punching, shearing, stamping and welding.

CUTTING

Today, many different processes of cutting are employed. While the oldest method of cutting is by using the saw, today, modern methods of cutting include laser, plasma and waterjet cutting. These methods of cutting vary in terms of the complexity and cost.

FOLDING

Many times, parts need to be bent and the most commonly employed method for bending is the use of the brake press. The brake press has died that form creases in the metal by pinching it. However, this method can be used only for very specific cases and depends on the shape of the dies and the movement of the part.

MACHINING

This process involves the removal of metal from a material. The machining process may be done using a lathe or some other cutting machine like a drill. In the case of a lathe, the material moves against it, while in the case of a drill the tool rotates in various ways against the fixed piece. The cutting head’s range of motion is specified by the number of axes.

PUNCHING

The punching process makes use of the punch and the die, where the die cuts out the piece of metal and makes a hole in it. The punch and the die must be the same size and shape as the desired hole. Sometimes the main piece is kept and the holes are made for the purpose of fastening, while in other cases, the portion that is removed is the required product, which is called the blanking.

SHEARING

This is a process in which a long cut is made on a metal piece and this process is usually done on sheet metal.

STAMPING

The process of stamping is similar to the process of punching, except that in stamping the material is not cut. The die is made in such a way that causes the material to be raised instead of penetrating the metal.

WELDING

This is essentially the process of joining two metal pieces. There are many kinds of welding methods that are used for different applications and metals used for the manufacturing process.

The process of fabrication has undergone several changes over the years with advancements in technology, there are newer processes and methods of fabrication that are developing each day. Each new day sees newer innovations such as 3D printing and fabrication is an area where the sky’s the limit.

 

A bike assembly is the combination of several different small components whose description is given below: -

The bike part assembly is divided in two parts: - 
                                                                             1. FORWARD PART
                                                                             2. REAR PART

1. FORWARD PART ASSEMBLY

1. HEAD PIPE: - It is the main part of the bike assembly through which our bike handle is attached these head pipes have diameter of 45 mm and having cross section length is 114 mm and having thickness of 0.25 mm

this pipe is further attached with the centre pipe LH/RH

2. CENTRE PIPE LH/RH: - These two centre pipes attached with the head pipe through welding all the joints are done through robotic hand welding the centre pipe is not directly attached with the head pipe 

3. MAIN PIPE: - It is the base pipe which is used to join the head pipe and the centre pipes LH/RH

3.PIPE SWING ARM PIVOT: - A circular pipe through which our bike stand is attached suitably       

4. LOWER LH/RH CENTRE PIPE: - these pipes attached with centre pipe LH/RH from one side and to head pipe to other side in forward part assembly

5. STIFNER SUB ASSEMBLY: - It is the part of forward assembly which is weld in between the F – 10 and F – 20 output and some of the other parts are also weld.

            1. stiffener pipe assembly                       4. main stand BKT

            2. front down pipe LH                               5. stiffener pipe – I, pipe – II

            3. front down pipe RH

Fig: - main stand BKT

          

6.BRACKET SAI MOUNTING: - This bracket is for mount the Sai unit in the bike assembly, these brackets installed in base – 4 modals just because of controlling the pollution

7.HEAD PIPE GUSSET: - It is an angular shaped sheet metal component weld at the head pipe and upper lower main pipe assembly for support the bike forward head portion

   

                                               Fig: - gusset head pipe

8.HORN BKT: - The bracket which is used to attached horn in the bike assembly

2.REAR PART ASSEMBLY

Fig: - rear part assembly

REAR UPPER PIPE: - These two rear pipes are attached to assemble different rear assembly parts like as bracket tank supporter, seat lock bracket, RR unit bracket, rear shocks bracket.

REAR LOWER PIPES: - These pipes are attached to support the lower assembly parts.

fig: - REAR LOWER PIPES

REAR SHOCKS BRACKET: - the joint bracket b/w two rear pipe LH/RH are known as the shocks bracket it is used to attached the shocker to a bike

9.BRACKET HT COIL: - A bracket mounting which is used to attached battery HT coil this battery HT coil provides the sudden ignition to our engine while suddenly stop

9.BRACKET TANK SUPPORTER: - The bracket tank which is used to fix the fuel tank position in the bike

Fig: - BRACKET TANK SUPPORT

BECK SEAT LOCK BRACKET: - This bracket is used to lock the back-seat assembly parts.

           

ENGINE BRACKET: - the bracket is used to hold the engine in b/w the assembly of bike suitably

           

R – R UNIT BRACKET: - R – R unit bracket is used to attached the r – r unit in the bike which provides the control on head light

PURGE VALVE: - these small parts are used for handle the external assemblies

3.SWING ARM

           

Fig: - Swing arm

It is part of bike through which a bike directly attached to the rear wheel or beck wheel not even wheel but chain, and shocker attachment is also possible through the swing arms.

A swing arm is also combination of many small parts also which are as follow: -

1.BUSH: - The part of swing arm by which swing arm is connected to bike rear and forward assembly parts

Fig: - BUSH

                     

2.REINFORCEMENT BKT: - bush is weld at top portion of this BKT through which our bike is connected there are 2 BKT LH/RH connected with each other through gusset.

3.REINFORCEMENT BKT RH: -   bush is weld at top portion of this BKT through which our bike is connected there are 2 BKT LH/RH connected with each other through gusset.

PARTS IN SWING ARM: -

GUSSET: - It is a H – SHAPED part which is used to attached two reinforcement legs of LH/RH at a particular distance.

There are many different small parts which are compulsory to attach A swing arm to bike frame which is shown in above figure like as shaft, cap/pivot  needle bearing oil seal, chain adjuster LH/RH etc.