JIG AND FIXTURE DESIGN FOR MOTORCYCLE ENGINE MOUNTING BASED ON THE PRO TABLE KIT SYSTEM

Abstract

This study focuses on the design of a jig and fixture for the Honda Vario motorcycle engine mounting component using a modular approach based on a 1400×800 mm Pro Table Kit with a 16 mm system. The design was conducted using Autodesk Inventor 2025, integrating the 3-2-1 locating principle, clamping system, and comprehensive CAM process simulation. The locator components designed include the ikel locator, head locator, V-block locator, and body clamp, each serving to optimally restrict the workpiece degrees of freedom. CAM simulation was performed on key jig components, covering facing, adaptive clearing, 2D contouring, peck drilling, and finishing strategies. The design results indicate that the Pro Table Kit-based jig system can accommodate the asymmetric geometry of the engine mounting with consistent repeatability. The component cost estimation based on the Bill of Materials amounts to IDR 4,166,631. The CAD/CAM approach has proven effective in identifying potential component interference and optimizing machining parameters before physical manufacturing processes are executed.