Master's Certification Program in Manufacturing Design
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Wiring harness flattening workbench
Flattening workbench settings
Flattening the 3D harness assembly
Modify flatten assembly
Saving the flatten Files
Drawing, creation & contents
This will be an introductory session where the basics of the automobiles and types of car bodies are explained. The complete vehicle development process which will explain the stages crossed by a car before it reaches the customer. The complete 3 years of development activity will be explained.
This will be an introductory session where the basics of the automotive BiW is taught. The basics of steel and its properties are covered, as steel is an important component used in the cars. Steps followed in the selection of the material is discussed. Also, the cross-functional teams are explained and the need to coordinate with them is explained with the master sections and 3D components of the parts for easy and clear understanding.
Out of all the BiW components, we will focus our attention on the hood, fender, roof, side and back doors. The design procedures for all the afore-mentioned parts can be summarized as follows.
In this, we will present a real-life scenario where the effect of converting an inner panel from aluminum cast to the steel deep draw part will be presented. Here is a quick summary of this case. The following design parameters were identified as critical and hence were fully described:
When you enroll in this course, you will be able to clearly understand these design parameters and the decisions that were made. In this case study, the design guidelines were set through a series of CAE simulations.
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
This section will have you covered in terms of the following basic concepts
For the uninitiated, we’ve also included a session on the basics of SOLIDWORKS where we take you through
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 more theory related to various concepts and terms used in mold design. The topics we shall cover are:
In the fifth theory session, we will be looking at the topic of sliders and ejection systems. The topics that will be covered are:
In the SOLIDWORKS session, we will be creating a mold for the outer cover of a disposable camera. The steps we will follow are mentioned below:
In the sixth-week theory session we will be learning about runners and gates. The various topics covered are as follows:
Then in the SOLIDWORKS session, we will be creating a mold for a door bezel model. Topics that will be covered are as follows:
In the seventh week, we will continue working on the door bezel model from the previous session and learn the following topics:
In the eighth week, we will start creating a mold for a CPU fan case model and we will learn the following topics:
In the ninth week, we will continue working on the CPU fan case model and we will learn the following topics:
In the tenth week, we will start creating a mold for a plastic knob model and we will learn the following topics:
We will also be covering some theory behind the cooling channels for a mold.
In the eleventh week, we will continue working on the plastic knob model and we will learn the following topics:
In the twelfth week, we will continue working on the plastic knob model and we will learn the following topics:
In this module, you will learn about the governing rules of GD&T. After this class, you will have an understanding of:
In this segment, you will study the following topics:
At the beginning of this section you will have built a good base for learning complex tolerances. In this section you will learn:
Position tolerance is the most widely used tolerance in GD&T.
In this section we will go through:
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 industry but are mentioned in the ASME standard
You will learn:
In this part, you will study complex GD&T drawings and understand every individual tolerance and the message the tolerance conveys.
We deal with the the working of Moldflow software & amp; the inputs required for running the analysis. Types of analysis that can be executed for validating the mold tool and for product development.
Designing in Moldflow (i.e.) how to create a node and various options used in the creation of nodes and in the same way line creation and surface creations are explained during this session. Creation of mesh/Mesh correction tools Mesh is the main requirement for running the analysis. The part is segmented into small triangles and that is called mesh. Creation of mesh and mesh correction tools are explained during this session.
Different types of meshes are used, depending upon the part geometry. How to create the other meshes and parameters that should be taken are explained.
The module used for analyzing the part, that is, selecting the analysis depending upon the objective or requirement will be explained in this session.
The cooling circuit plays the main role in maintaining the temperature inside the mold. Many features are there in the cooling circuit and how to design that design features are explained in this session.
For cooling analysis, different types of coolant and modifications are required to optimize the mold tool. All the settings details will be explained.
This is an advanced type of cooling analysis where the molding tool is also analyzed. The setup for this analysis is explained.
The result obtained with different types of analysis is discussed here. The result interpretation and the basic solutions are discussed here.
The result obtained with different types of analysis is discussed here. The result interpretation and the basic solutions are discussed here.
WEEK 1
Designing in Moldflow (i.e.) how to create a node and various options used in the creation of nodes and in the same way line creation and surface creations are explained during this session.
Various methods of creating nodes.
Creation of lines and curves in different methods.
Creation of conformal cooling lines.
Creation of regions by using different options available.
Creation of local coordinate system.
WEEK 2
Designing a Marker pen model with the help of tools that was introduced in the previous week's challenge. After creating the geometry you will be taught how to generate a Dual domain mesh.
Setting up the geometry for meshing.
Checking and clearing the errors that can happen in the mesh.
Fixing the aspect ratio issues.
Checking the orientation of the mesh.
Checking the connectivity issues in the model.
Clearing the collapsed faces.
Overlap diagnostics.
WEEK 3
A) Generating a Midplane mesh out of a Dual domain mesh
Clearing the free edges present in the geometry.
Checking the thickness assigned to the midplane mesh that is generated.
Checking the orientation of the model.
B) Generating 3D mesh in the geometry.
Advancing front mesher
Advancing layer mesher
Tetra Advanced
WEEK 4
Detecting the errors that can happen in a 3D mesh and its rectification
Inverted Tetras
Creating a ruler geometry and performing different types of meshes in it to show how mesh errors can be fixed in severe cases.
WEEK 5
In this module you will be introduced to initial analysis which will help in determining the gate location, fill time and packing etc.
Gate Location Analysis
Molding Window Analysis
Fill Analysis
Fill+pack Analysis
Creating a Gating system which includes
Creating the cold sprue
Creating the cold runner
Creating the cold gating system
WEEK 6
Learning how to select the suitable material for the analysis.
Selection of the manufacturer and the trade name for the selected material.
3 levels of material Quality Indicator
Fill Quality Indicator
Pack Quality Indicator
Warp Quality Indicator
Introduction to Process setting Wizard
Setting up the values in the process setting wizard that is required to run the analysis.
Setting up the ruler Geometry to run Fill+pack+warp Analysis
Introduction to Optimization methods.
Parametric Study.
Design of experiments (DOE)
WEEK 7
Explanation of the various results after running the Fill+pack+warp Analysis.
Results such as Fill time, Pressure at V/P Switchover, Volumetric shrinkage at ejection, Time to reach the ejection temperature, %shot weight XY plots, Air traps, Average velocity, Clamp tonnage, Weld lines, Meld lines, Deflection in all directions, Warpage
These results will be explained and if there are any defects then the remedies will also be explained.
WEEK 8
For this week you will be equipped with how to create a COOLING CIRCUIT DESIGN for the ruler geometry which you created in the previous sessions.
The cooling circuit plays the main role in maintaining the temperature inside the mold.
The weeks content covers topics such as:
Creating cooling circuits.
Creating Baffles and Bubblers
Selection of coolants
Cooling circuit Inserts
You will also be creating a Glass tumbler geometry and creating the whole cooling circuit for the model including baffles and bubblers in it and making it ready to run the simulation.
WEEK 9
Here initially you will be setting up the case for the ruler geometry and running a cooling analysis on it.
Thereafter you will be setting up the case for the Glass Tumbler Geometry and making it ready to run the cooling analysis.
You will be introduced to the results obtained from the analysis.
Benefits of adding chiller circuits and how to set it up will be learned.
WEEK 10
In this module you will be introduced to Transient Cooling Analysis.This is an advanced type of cooling analysis where the molding tool is also analyzed. The setup for this analysis is explained.
Setting up the case for Glass Tumbler geometry to run a Cool+Fill+Pack+Warp Analysis using FEM solver.
Setting up the case for Ruler geometry to run a Cool+Fill+Pack+Warp Analysis using BEM Solver.
Setting up a Mold Block for Cooling Analysis.
Beryllium-Copper Inserts.
WEEK 11
Analyzing the results using different solvers in different models.The result obtained with different types of analysis is discussed here. The result interpretation and the basic solutions are also explained.
Cooling Analysis results using BEM Solver
Cooling Analysis results using FEM Solver
WEEK 12
The result obtained with different types of analysis is discussed here. The result interpretation and the basic solutions are discussed here.
How to generate a proper report in order to substantiate the results that you obtained with the help of Moldflow.
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Graduate Engineering Trainee @ EASI Engineering Services Pvt. Ltd.
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