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| | == Introduction == | | == Introduction == |
| − | [[Image:bike.jpg|thumb|alt=Puzzle globe logo|Beginner Cruiser Motorcycle]]
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| | We are a group of five students in MAE 277, Intro to Mechanical Engineering. This semester we have been given a reverse engineering project based on an assigned product. Through detailed dissection, analysis, and reassembly we have put together this report in summary of our work with the Beginner Cruiser Motorcycle. This bike is as small, gas powered, cruiser inspired, recreational motorcycle. | | We are a group of five students in MAE 277, Intro to Mechanical Engineering. This semester we have been given a reverse engineering project based on an assigned product. Through detailed dissection, analysis, and reassembly we have put together this report in summary of our work with the Beginner Cruiser Motorcycle. This bike is as small, gas powered, cruiser inspired, recreational motorcycle. |
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| − | [http://gicl.cs.drexel.edu/wiki/Group_21_-_Beginner_Cruiser_Motorcycle_-_Request_for_Proposal Request for Proposal]
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| − | [http://gicl.cs.drexel.edu/wiki/Group_21_-_Beginner_Cruiser_Motorcycle_-_Preliminary_Design_Review Preliminary Design Review]
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| − | [http://gicl.cs.drexel.edu/wiki/Group_21_-_Beginner_Cruiser_Motorcycle_-_Coordination_Review Coordination Review]
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| | ==Executive Summary== | | ==Executive Summary== |
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| | We completed the reverse engineering analysis of the Beginner Cruiser Motorcycle successfully with a full disassembly and reassembly. While the project was difficult and required much hard work, we are exited about what we have learned as well as the information we are presenting here about our product. | | We completed the reverse engineering analysis of the Beginner Cruiser Motorcycle successfully with a full disassembly and reassembly. While the project was difficult and required much hard work, we are exited about what we have learned as well as the information we are presenting here about our product. |
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| | + | [[Image:bike.jpg|thumb|alt=Puzzle globe logo|Beginner Cruiser Motorcycle]] |
| | '''Request for Proposal''' | | '''Request for Proposal''' |
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| | + | [http://gicl.cs.drexel.edu/wiki/Group_21_-_Beginner_Cruiser_Motorcycle_-_Request_for_Proposal Request for Proposal] |
| | *Outline of our goals for the project, our deadlines, meeting schedules, and collaboration with Group 21. | | *Outline of our goals for the project, our deadlines, meeting schedules, and collaboration with Group 21. |
| | *Introducing Group Members and their background experience. | | *Introducing Group Members and their background experience. |
| | *Initial evaluation and general inferences about the product. | | *Initial evaluation and general inferences about the product. |
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| | '''Preliminary Design Review''' | | '''Preliminary Design Review''' |
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| | + | [http://gicl.cs.drexel.edu/wiki/Group_21_-_Beginner_Cruiser_Motorcycle_-_Preliminary_Design_Review Preliminary Design Review] |
| | *Identifying and trouble shooting any problems or any obstacles we may see in the future. | | *Identifying and trouble shooting any problems or any obstacles we may see in the future. |
| − | *Step by step procedure of the Disassembly Procedure. | + | *Step by step description of the Disassembly Procedure. |
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| | '''Coordination Review''' | | '''Coordination Review''' |
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| − | ==Critical Design Review==
| + | [http://gicl.cs.drexel.edu/wiki/Group_21_-_Beginner_Cruiser_Motorcycle_-_Coordination_Review Coordination Review] |
| − | | + | *List of Engine components, their materials, and why those materials were chosen. |
| − | ===Product Reassembly===
| + | *List of problems identified with the product and revisions we would make to improve them. |
| − | | + | *Solid Modeling of several important parts of bike. |
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| + | *Summary of an Engineering Analysis problem that might be done to this product. |
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| − | ====Front Reassembly====
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| − | '''Front Fork:'''<br>
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| − | *The first step of the reassembly you must slide the fork back into the frame of the bike. Then screw back on all the nuts and then tighten them to a secure level.
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| − | **Difficulty: 2
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| − | {|
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| − | | [[Image:11.JPG|thumb|]]
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| − | | [[Image:12.JPG|thumb|]]
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| − | |}
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| − | '''Handle Bar:'''<br>
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| − | *First attach handle bar bracket by securing the two bolts on the underside of the fork. Then slide the handle bar back in place and screw down the top of the handle bar holder with the 4 screws. | + | |
| − | **Difficulty: 1 | + | |
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| − | | [[Image:10.JPG|thumb|]]
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| − | |}
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| − | '''Kill Switch:'''<br>
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| − | *Attach black wire to plug and screw grounding washer back into place.
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| − | *Reattach clamping metal piece on backside of kill switch with 2 Phillips head screws.
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| − | **Difficulty: 2
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| − | {|
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| − | | [[Image:8.JPG|thumb|]]
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| − | | [[Image:9.JPG|thumb|]]
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| − | |}
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| − | '''Throttle Grip:'''<br>
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| − | *Slide grip back on to handle bar and place opposing black throttle pieces in place to be tightened. Then insert small black plastic piece at the end of the cable in place. Fasten screws in slots holding Throttle and grip together.
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| − | **Difficulty: 1
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| − | {|
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| − | | [[Image:6.JPG|thumb|]]
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| − | | [[Image:7.JPG|thumb|]]
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| − | |}
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| − | '''Headlights:'''<br>
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| − | *Place headlight in bracket located on top middle of front fork and slide bolts through both holes. Then tighten both nuts with wrench until light cannot be moved. | + | |
| − | **Difficulty: 1
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| − | {|
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| − | | [[Image:5.JPG|thumb|]]
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| − | | [[Image:4.JPG|thumb|]]
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| − | |}
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| − | '''Front Fender:'''<br>
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| − | *Carefully place fender in place lining up fender brackets with the holder (above fender) in the middle of the front fork. Slide bolts through and tighten bolts.
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| − | **Difficulty: 2 | + | |
| − | {|
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| − | | [[Image:3.JPG|thumb|]]
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| − | | [[Image:2.JPG|thumb|]]
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| − | |}
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| − | '''Gas Tank (Fake):'''<br>
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| − | *Place tank on frame so the underneath bracket lines up with holes on frame. Then tighten nuts from underneath so tank holds in place.
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| − | **Difficulty: 1
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| − | '''Front Tire:'''<br>
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| − | *Hold frame over tire and slide axle through fork, wheel and other side of fork. Tighten Nut on exiting side till wheel is secure.
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| − | **Difficulty: 2
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| − | {|
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| − | | [[Image:1.JPG|thumb|]]
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| − | |}
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| − | ====Engine Reassembly====
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| − | '''Crank Cover:'''<br>
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| − | *Slide the slide cover down the driveshaft, and rotate until the screw holes line up. Insert bolts (6) using 10 mm socket.
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| − | **Difficulty: 2
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| − | '''Head, Head Cover:'''<br> | + | '''Critical Design Review''' |
| − | *Put push rods into their holes. Slide the head over the push rods and onto the top of the cylinder making sure all the holes line up. Insert and tighten bolts (4) holding down entire head assembly using 12mm socket. Make sure the push rods are sitting in the cups of rocker arms. Place head cover over the rocking arms. Insert and tighten bolts (4) holding down head cover using 10mm socket.
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| − | **Difficulty: 2
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| − | {|
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| − | | [[Image:34d.JPG|thumb|]]
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| − | | [[Image:32d.JPG|thumb|]]
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| − | '''Magneto and Spark Plug:'''<br>
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| − | *Screw the spark plug into its hole until it is tight using a 13/16 socket. Fold a piece of paper 3 or 4 times. This is to create a spacer to make sure when you put on the magneto, it is not too close or far away from the flywheel or the magnet on it. Hold the magneto in front of its holes on the engine block. Wrap the paper around the flywheel and let the magneto stick to it via magnetism. Insert and tighten bolts (2) using 12mm socket. The magneto might need to be adjusted so that the holes line up. Remove the paper, the magneto should have about 1/32 clearance from the flywheel. Rotate the flywheel to make sure it does not come close at any point. Slide the rubber plug onto the spark plug.
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| − | **Difficulty: 3
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| − | {|
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| − | | [[Image:39d.JPG|thumb|]]
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| − | '''Carburetor, Throttle:'''<br>
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| − | *Screw the throttle assembly to the engine block using a wrench. Slide the governor arm onto the plastic axle and slide the pin through it. Connect the black spring to the throttle assembly and connect the brass spring to the first hole on the governor arm using needle nose pliers. Slide the carburetor onto the two parallel bolts on the engine block, as you are sliding it on slip the connecting rod from the governor arm into the black plastic throttle control on top of the carburetor. Slide the gasket on after the carburetor, then finally the black plastic carburetor cover. Tighten nuts (2) holding carburetor cover and carburetor onto engine, using pliers.
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| − | **Difficulty: 4
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| − | '''Air Filter and Cover:'''<br>
| + | [http://gicl.cs.drexel.edu/wiki/Group_21_-_Beginner_Cruiser_Motorcycle_-_Critical_Design_Review Critical Design Review] |
| − | *Screw the two screws through the base of the air filter case with a Philips head screw driver into the top of the carburetor cover. Slide the air filter onto the base, tighten down with the first wing nut. Slide the air filter cover over the top of air filter and tighten down with second wing nut.
| + | *Step by step description of the Reassembly Procedure. |
| − | **Difficulty: 2
| + | *Summary of the Reassembly Process and its success. |
| − | {|
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| − | | [[Image:12d.JPG|thumb|]]
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| − | '''Exhaust:'''<br>
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| − | *Attach the exhaust and muffler by sliding it onto the two bolts on engine block next to the exhaust hole. Tighten nuts (2) onto bolts (2) using 12mm socket. Place the heat shield over the muffler, insert and tighten screws (4) with a Philips head screw driver. | + | |
| − | **Difficulty: 1
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| − | {|
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| − | | [[Image:27d.JPG|thumb|]]
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| − | | [[Image:28d.JPG|thumb|]]
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| − | |}
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| − | '''Gas Tank:'''<br>
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| − | *Lower gas tank into place, and slice the rubber hose under the throttle and down to the carburetor. Slide it onto the brass fuel tube. Slide the wire clamp into place. Insert bolt next to throttle and tighten with needle nose pliers. Tighten two nuts to bolts on tank with pliers
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| − | **Difficulty: 1
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| − | {|
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| − | | [[Image:18d.JPG|thumb|]]
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| − | |}
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| − | '''Flywheel Cover:'''<br>
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| − | *Place flywheel cover over fly wheel making sure all holes line up. Insert and tighten bolts (4) using a 10mm socket.
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| − | **Difficulty: 1
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| − | | [[Image:55d.JPG|thumb|]]
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| − | '''Pull-Start Assembly:'''<br>
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| − | *Coil spring around inner wheel, such that the spring starts in the pre-cut groove and wraps around accordingly. Un-knot pull rope, and slide on the pull-grip, and tie off, so that it doesn’t fall off. Pull rope through hole in pull-start main housing, and then into the slot in the center wheel. Tie off rope end and fit snug inside the space allowed for the rope. Wind rope around inner wheel, then place inner wheel, with spring facing the main housing, into the main housing. Fit in the brass pins, and put in small springs which cause the brass pins to be pushed in towards the center of the wheel. Now attach the top cover to the inner wheel, using a washer and screw. Pull rope out as if you were to start up the motor, but slowly. The spring tension is now tight enough to retract, but the rope needs to be re-wound…with everything in place, wind rope using the access slack. Now pull the rope once again, the rope should retract once again…if not, repeat step 9. If a small amount of rope is left after the spring retracts, simply retie a knot to make the grip be right up against the housing, and then cut off access.
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| − | *It is not recommended to take a apart a pull start for the spring can cause injury while being wound, or if it gets released without the assembly being together. Rebuild using extreme caution. | + | |
| − | *Screw the pull start onto the fly wheel cover with bolts (3) using 8mm socket.
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| − | **Difficult: 5
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| − | {|
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| − | '''Heat Plate:'''<br>
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| − | *Hold heat plate to engine block underneath cylinder so that the three holes line up. Insert and tighten bolts (3) using a 10mm socket.
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| − | **Difficulty: 1
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| − | '''Clutch Bracket Plate:'''<br>
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| − | *Align holes on plate with holes in engine block. Insert and tighten bolts (4) using a 12mm socket.
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| − | **Difficulty: 1
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| − | {|
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| − | | [[Image:1d.JPG|thumb|]]
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| − | '''Clutch:'''<br>
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| − | *Slide clutch onto driveshaft making sure key and groove line up. Insert and tighten bolt and washer into end of driveshaft using 12 mm socket.
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| − | **Difficulty: 3
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| − | {|
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| − | | [[Image:1d.JPG|thumb|]]
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| − | ===Final Assembly Evaluation:===
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| − | *The bike ran well when we were given it and to our excitements runs again after we have disassembled it. We are also proud to say that it is faster than it was when we first tested it. After changing the max position of the throttle, and increasing the idle to just below the clutch’s engaging rpm’s we saw a noticeable increase in the bikes performance. The only negative changes to the bike after the dissection are a broken headlight bulb, and masking tape holding cables to the frame instead of the original zip tie which had to be cut. The head light bulb was probably broken when all of our disassembled pieces were moved across the shop without our knowing. While it is still intact it does not illuminate.
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| − | *All of the same tools were used in disassembling and assembling the bike. Besides substituting masking tape for the zip tie the bike is back to its original assembly.
| + | ==References== |
| − | *The reassembly of the pull start proved to be incredibly difficult, and required much more attention in putting it back together than taking it apart. The throttle and governor proved a little difficult as the idle speed was too high at first and the bike idled at rpm’s well above the clutch’s engaging speed. After finding the sweet spot right below the point of clutch engagement the problem was solved.
| + | No outside information was used in making this project. All included information is based on previous knowledge, lessons from class, or gained experience from the dissection. |
We are a group of five students in MAE 277, Intro to Mechanical Engineering. This semester we have been given a reverse engineering project based on an assigned product. Through detailed dissection, analysis, and reassembly we have put together this report in summary of our work with the Beginner Cruiser Motorcycle. This bike is as small, gas powered, cruiser inspired, recreational motorcycle.
We completed the reverse engineering analysis of the Beginner Cruiser Motorcycle successfully with a full disassembly and reassembly. While the project was difficult and required much hard work, we are exited about what we have learned as well as the information we are presenting here about our product.
No outside information was used in making this project. All included information is based on previous knowledge, lessons from class, or gained experience from the dissection.
