In this course, you will learn about the solid modelling and surface modelling tools of the CAD software - SOLIDWORKS. SOLIDWORKS is a dynamic software used primarily in R&D sectors. SOLIDWORKS is widely used in the concept generation stage of production. It gives designers real-time results in product modelling.

Students from mechanical engineering can enrol in this course. In this course, you will be learning the fundamentals of concept generation.

At the end of this course, you will be fluent in both solid as well as surface modelling tools. After the completion of this course, you will become eligible for the role of a CAD engineer using SOLIDWORKS. This course is specifically designed for design engineers who are interested in the product concept generation phase. After the completion of this course, you will understand the basics of SOLIDWORKS including - part modelling, assembly modellings, photo-realistic renderings.

             

You will learn to create professional mood boards and initial ideation sketches in Adobe Photoshop. You will learn how to import & blend images, add watermarks and color. You will also learn how to design an American Chopper and how to render this design in Photoshop.

• You will be introduced to SOLIDWORKS and will learn how to customize the shortcuts. You will learn solid modelling techniques in SOLIDWORKS while modelling the Transmission belt, Kickstand, and Fenders of an American Chopper. You will also learn how to add appearance to the parts of the bike. 

• In this module, you will learn how to create advanced sketches using curved driven patterns and patterns such as sketches, projected, and composite curves. You will also learn how to create complex shapes while modelling the wheels, chassis, and engine.

• You will learn the use of mates to provide relationships between parts in an assembly. You will also learn how and why advanced mates such as angle mates are provided to limit the rotation of parts.

In this module, you will learn how to add decals, lights, and cameras as a preprocessing step before the final rendering. You will be taken through the complete rendering process with PhotoView 360 and SOLIDWORKS Visualize using which you will be creating high-quality images during the final rendering.

In this module, you will learn about the surface modelling feature in SOLIDWORKS. You will learn how to create a part using a reference surface. You will be taught advanced surface modelling features while creating various parts of the Yacht such as Hull, the Superstructure, and Seats. You will learn how to add decals and appearance for the parts and assembly.

• Transmission belt, front & rear fender modelling
• Chain, side stand & pedals modelling
• Front & rear wheel modelling
• Engine modelling
• Chassis for American Chopper designing
• Front fork designing
• Oil tank designing
• Creating the assembly of American Chopper
• Performing the rendering on assembly created by using Photoview 360 and SOLIDWORKS Visualise as the rendering tool

Sheet Metal application provides an environment for the design of sheet metal parts used in machinery, enclosures, brackets, and other parts normally manufactured with a brake press. Siemens NX sheet metal design software incorporates material and process information in sheet metal-specific modelling features: bends, flanges, tabs, cutouts, beads, dimples, louvres, corner and edge treatments, patterns, and other formable features. You can also quickly convert solid models to sheet metal components, and create sheet metal parts that enclose other components. More than 85% of Sheet metal industries use NX CAD as a design tool. 

You will learn the Sheet Metal module of NX CAD [UG NX] software. At the end of this course, you will be able to implement sheet metal design constraints. You will also be able to easily create real-time industry models of sheet metals. 

In this module, you will learn how to create the sketches in NX CAD

• Creation of lines, circles and squares
• Specifying the dimensions
• Pattern creation
  

Understanding Tabs and Flanges

• Contour flange
• Advanced flange
• Jog flange
• Hem flange
• Corners, closed corners & overlapping corners in sheet metals

Adds a flange to an angle to a planar face and adds a bend between the two.

Creates a base feature by extruding a sketch along a vector, or adds material by sweeping a sketch along an edge or chain of edges.

Advanced flange

Joggles

Lightning Cutouts

In this module, you will get a thorough understanding of:

• Edge rip
• Convert utility
• Cleanup utility
• Reliefs 
• Face optimization 
• Forming sheet metal from solid

In this module, you will gain experience in:

• Beads creation
• Dimple creation
• Emboss creation
• Mirror features
• Feature patterns

• Neutral file data
• Surface extraction 
• Adjacent and tangent face selections 
• Flattening & Thickening 

In this project, the student will create application-oriented features such as beads, hinge creations, hem flange creations.

In this project, students will learn the applications of louvers in the creation of ventilation for electric casings. Students will also understand the importance of dimple creations in sheet metals in this project.

Here you will learn how to create sheet metal enclosures for unconventional parts.

In this project, students will develop the skills required for modelling 3D models by using 2D inputs. Students will also understand the applications of stiffening features in sheet metals. 

Geometric Dimensioning and Tolerancing (GD&T) is a quality control method that is used for defining allowable variation in size, form, orientation, and location using symbols. The purpose of GD&T is to precisely define parts and assembly geometry.

In this course, you will learn about the Siemens NX CAD software for design, assembly, and drafting of parts. You will train in industry best practices for design and drafting for the proper manufacturing of components. You will also learn the application of different tolerance symbols and datums for parts and assemblies with practical examples. You will work on a project that will introduce you to drafting using the GD&T application by designing a butterfly valve. 

• Difference between traditional dimensioning and GD&T
• Benefits of GD&T
• How to read a feature control frame
• Technical standards- ASME Y14.5M-2009
• Different symbols used in GD&T, cover, and feature of size

In this module, you will learn about the governing rules of GD&T. After this class, you will have an understanding of:

• Rule No. 1 (i.e. Taylor principle a.k.a envelope principle)
• Rule No. 2 (Regardless of feature size)
• 14 symbols used in GD&T
• Flatness, straightness, cylindricity, and circularity tolerances
• MMC, LMC, and RFS conditions
• Various examples for form tolerances

In this segment, you will study the following topics:

• What are datums and how to apply datums to parts
• Datum reference features
• Datum feature modifiers
• How to calculate virtual condition
• Conjugated datums

At the beginning of this section, you will have built a good base for learning complex tolerances. In this section you will learn:

• Profile of a surface and profile of a line
• Perpendicularity tolerance, parallelism tolerance, and angularity tolerance
• Composite profile tolerance
• Various examples for orientation and profile tolerances

Position tolerance is the most widely used tolerance in GD&T.

In this section we will go through:

• Understanding true position
• Projected tolerance
• Composite tolerances
• Tolerance zones- cylindrical, rectangular, spherical
• Examples of position tolerance

By now, you will have enough knowledge to read an entire GD&T drawing and understand it. In this section, you will learn about some tolerances that are not widely used in the industry but are mentioned in the ASME standard

You will learn:

• Coaxiality
• Symmetricity
• Circular and Total Run Outs
• Examples

In this part, you will study complex GD&T drawings and understand every individual tolerance and the message the tolerance conveys.

This is an introductory session where students are introduced to the basics of automobiles along with different models of car bodies. Students will also learn about the different stages of vehicle development that a car will go through before reaching the customer. Students will also learn about the three years of development activity.

• In this session, the student will be introduced to the basics of automotive BiW. The basics of steel and its properties are covered in details because steel is an important component used in automobiles. The steps that are followed in the selection of the material will be discussed as well. Studnets will be given an introduction into the cross-functional teams and the need to coordinate with them along with examples of master sections and 3D components of the parts for easy and clear understanding.

We will focus our attention on the Hood, Fender, Roof, Side doors, and Back doors. The design procedures for all the afore-mentioned parts can be summarized as follows.

• Design Requirements
• Functional Requirements
• Regulations
• Gap and Flushness Requirements
• Safety Requirements

In this module, you will first learn the anatomy of a Locker and Striker mechanism. In order to be a successful product development engineer, it is very important to understand in detail the development process and design requirements for even the tiniest components. In this module, we will be analyzing the locker and striker mechanism in detail.

In this module, we will look at two case studies. Both of these studies focus on supplier manufacturing practices. We will discuss the design challenges faced by two Asian Automotive suppliers and then go over the solution methodologies

• In this particular project, you will be working on designing the drip area for the given fender, where you will make sure to follow certain dimensions that are required to be followed for the drip area.
• In addition to that, you will also provide the necessary bead and other emboss to strengthen the component.
• You will make sure that the output part meets all the tolerances that need to be satisfied for the deep drawing process.

You will learn about the following topics, 

• Product life cycle
• Design life cycle

You will learn about the following, 

• Types of plastics (thermoset plastics, thermoplastic)
• Engineering plastic materials
• Manufacturing process
• Injection molding

You will learn about the following,

• Basic commands and operation.
• Save, pan, rotate etc.

You will learn about the following, 

• Commands, 
• Rules to follow
• Working in exercise

You will learn about the following, 

• Pad, pocket
• Working on exercise

You will learn about the following, 

• Boolean operations
• Working on Boolean exercise
• Working on after tool go modification on automotive components. (OEM working procedures)

You will create a PCB Bracket using Boolean operations

You will learn about the following, 

• Commands (Types of Sweep)
• Working on exercise
• Draft analysis
• Working on surface exercise

You will learn about the following, 

• Commands 
• Creation of Closed body, Thickened body
• Parting line, parting surface

You will learn about the following, 

• How to create a tooling direction and do the draft analysis to ensure the part can be taken out of tool
• Adding the right thickness to the part and solve the issues
• Create the parting line for the bezel

In this section,

• We will learn on what is a mounting feature
• How to create a locator and dog house
• Integrating the mounting features to the base part with Boolean operations

We will learn,

• What is the clip mounting feature in plastic design
• Design considerations for creating this feature
• Tooling analysis for the clip feature

• Drafting work bench.
• Creation of detail drawing for the components
• Views creations (basic view & section views)
• Application of GD&T in drawings
• Template settings

• Creation of paring line
• Creation of tooling axis
• What is undercut and how to solve it

• Creation of simple mold for the rear quarter trim cup-holder
• What is core and cavity
• Stripper, ejection and system
• Draft analysis
  

Designing a mold gives a good working understanding in the molding aspects of a component

• Instrument panel bezel with undercut
• Creation of mold with side core, and lifter
• Clear picture of undercut and other tooling complications
• Draft analysis for complex part

• Plastic defects faced in automotive design
• Real-time examples and solution for these designs

• Component out of complex class-A surface
• Solving class-A before starting design (OEM procedure)
• Complex surfaces that cannot be thickened easily
• Draft analysis to check the part for tooling.
• OEM standard output presentation

• Assemble automotive sub-assemblies including child part, screws  
• How to create assemblies in CATIA
• Creating constraints
• Assembly sectioning analysis
• Proximity analysis and output preparation.
• Compare analysis of 2 similar components OEM working procedure

• Develop door trim from surfaces, and master section
• Develop fixation and feature from door trim
• Develop switch bezel from studying master section.  
• Gap and flush analysis
• OEM standard output presentation

Creating the CAD model of switch bezel from the following inputs 

• Given Class A surface 

• Plastic component thickness

• Draft angle requirements

• Create the draft direction for manufacturing using the injection molding technique 

• Class B creation by maintaining a constant thickness 

• Closing surface creation based on proper draft angle and parting line for core and cavity design 

Creating a solid model of coin holder from given Class A inputs

• Check for draft analysis and make modifications 

• Modify class A to meet the requirements. Prepare a report of changes made to Class A

• Follow the procedure to create the solid model following plastic component design  techniques 

• Check if the product can be manufactured by using draft analysis.

Create a B pillar from the given class A with engineering features

• Create a solid model from the given class A by following plastic design rules 

• Prepare dog houses and locators for matching the part with main B pillar 

• Create the location for proper fixing of part 

• Add rib feature to add strength to part 

• Do draft analysis with respect to main tooling direction and slider direction.

Creating heat stakes for joining the plastic door applique to the metal substrate

• Design the 4 way and 2-way locators for the plastic applique 

• Understand the heat staking process

• As per the design rules design the heat stakes to join the door applique with the metal part. 

This section will cover the following basic concepts

• Injection molding process and how it works
• Plastic processing methods such as 

• Rotational molding

• Extrusion

• Vacuum forming

• Blow molding

• Gas-assisted injection molding

• Mold cycle and the factors affecting it
• Thermoplastics and thermosets
• The current trends in the industry
• The types of plastics being used
• The properties of these plastics and, 
• How to select them

For the uninitiated, we’ve also included a session on the basics of SOLIDWORKS where we take you through

• Basics of sketching
• Basics of using features in SOLIDWORKS

After getting a basic understanding of injection molding from the previous session, in this session we will jump into the technical side of designing the mold.

The topics we will be covering are:

• How the product development process takes place in the plastic industry
• Various departments in plastic manufacturing industries and the workflow
• Parts of mold - core, cavity, guide pillar, sprue, register ring, guide bush, ejector pin,  return pin, spacer blocks, core plate, cavity plate, ejector plates, etc.
• 2 plate & 3 plate molds
• Drafts
• Parting lines 

  In the SOLIDWORKS session, we will continue where we left in the previous session and learn about the various surface tools used for designing.

In the third week, we will be covering theory related to various concepts and terms used in mold design. The topics we shall cover are:

• Concept of machine tonnage and how to calculate it
• DFM study where we will look at various concepts such as gate point, wall thickness, cores, tolerance, venting, ejector pads, inserts, ejector inserts, guide pillar, support block, relief, free play inserts,  multi-gate position, and flow leader.
• Various defects that may occur during the mold design process such as short shot, flash, weld lines, sink marks, blisters, jetting, burn marks, warpage, gloss differences, hesitation, overpacking, and unbalanced flow.

In the fourth week, we will be studying the theory behind parting surfaces. The topics that will be covered are as follows:

• What is a parting surface?
• Types of parting surfaces such as flat, stepped, angled and profiled parting surfaces
• Example cases where we will try to understand the selection of parting surfaces
• Matching drafts
• Shrinkage 
• Inserts 

In the SOLIDWORKS session, we will start with our first mold design tutorial. We will be covering a simple plastic component and we will learn the following:

• Doing draft analysis for the model
• Creating parting lines
• Creating shut-off surfaces
• Creating parting surfaces
• Create basic mold blocks

In the sixth week theory session we will be learning about runners and gates. The various topics covered are as follows:

• Types of gates such as sprue, edge, tab, overlap, fan, disk, ring, spoke, film, pin, submarine and cashew gates.
• Runner diameter calculation
• Types of runners
• Runner configurations
• Why engravings are used in cavity

Then in the SOLIDWORKS session, we will be creating a mold for a door bezel model. The topics that will be covered are as follows:

• Creating the parting lines, shut-off surfaces and parting surfaces of 3D profile for the model.
• How to work in assemblies and how to arrange files in a specific format.
• How to align the sprue of the mold with the origin of the assembly.
• How to select proper dimensions for the mold blocks.
• Creating mold blocks for door bezel.

In the seventh week, we will continue working on the door bezel model from the previous session and learn the following topics:

• Locating undercuts in the model and understanding how the use of sliders will help in solving the undercut issue.
• Creating slider split
• How to assign proper dimensions to the slider
• Editing the core cavity blocks according to the shape of the slider.
• Creating bolts, washers and locking mechanism for the sliders.

In the ninth week, we will continue working on the CPU fan case model and we will learn the following topics:

• Locating undercuts in the model 
• Creating a slider split for the undercuts.
• Assigning proper dimensions for the sliders.
• Providing reliefs for the sliders.
• Creating inserts for the model.

In the twelfth week, we will continue working on the plastic knob model and we will learn the following topics:  

• Creating an ejector system which will include the angled ejector pins, reliefs, ejector plates and ejector back plates.
• How to make the channels for plastic injection which will include the sprue, runner and gate for the mold.
• Understanding the use for providing air vents in a mold and then creating channels for the passage of air from the mold.
• How to select the dimensions and positions of the cooling channels in the mold and how to create them