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In this paper, the study of plastic bonded magnetic material is studied for the surface adhesion of the material on to the surface of a metal cup. The bonded magnetic material is formed as a mixture of plastic material blended with ferrite or NdFeB Magnetic powder. The amount of magnetic material used is confined to the magnetic property of the magnetic powder that can exhibit the required magnetic performance as higher rotational speed and higher temperature. The magnet is injection moulded onto the outer circumference of the metal cup. The magnet is bonded onto the metal surface which is of cup shape and this assembly is magnetized to form a multipole magnet. This multipole magnet is designed to withstand high centrifugal force during the magnet rotation at higher rpm say 40000 rpm.

Global Automotive Industry is mandated with the task of emission reduction and mileage improvements. One of the key areas being looked at from mileage standpoint is light weighting. While Aluminum body is replacing Steel is many vehicular applications, in Starter Motor Aluminum is the key component. Therefore, any attempt at light weighting must consider Aluminum. A Starter motor fits directly on to the engine. Aluminum being the housing material provides structural stability. It also performs the role of heat dissipation being a good thermal conductor and source of electrical ground path. Aluminum constitutes 20 - 25% of Starter motor weight. Any significant weight reduction cannot be achieved unless we look at the components made of Aluminum, namely die cast Housing and End plate. The alternatives considered in this study include engineered plastics, magnesium alloy and composites.

Magnesium alloy current being used for automotive sector and are being significantly used for manufacturing engine block as offering higher power to weight ratio to the vehicle. In this context, the magnesium alloy has been used in the replacement of aluminium alloy for the starter housing which in turn increase the power to weight ratio of the motor. Considering the operation condition of starter motor in the engine of the vehicles, the starter motor is being exposed to the harsh environment, where its system is being tested for Noise, Vibration and Harshness. In this paper, the magnesium alloy housing is used to study the vibration and noise developed in the starter motor and the same is compared with the noise and vibration of the motor when it being used with Aluminium alloy Housing. First, the vibration study is carried out for the housing part alone to capture the resonant frequency of the both housing alloy say, Aluminium and Magnesium.