Master's Certification Program in Manufacturing Design

Master's Certification Program in Manufacturing Design

  • Pre-requisites : For Mechanical & Automotive Engineers
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A Quick Overview

Master's Certification program in Manufacturing Design is a 6 month long, intensive program. The program comprises of 5 courses that train you on all the essential engineering concepts and tools that are essential to get into top OEMs.
 
Courses included:
  1. Wiring Harness using CATIA V5
  2. BIW fixture design using CATIA V5
  3. Automotive Sheet Metal Design using NX CAD
  4. Mold design using SolidWorks
  5. Geometric Dimensioning and Tolerancing using NX CAD

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Wiring Harness using CATIA V5 SYLLABUS

1Basics of Vehicle Electrical Distribution System & Wiring Harness

 

  • Introduction to Vehicle Electrical Distribution System (EDS) 
  • Introduction to wiring harness assembly
  • Wiring harness design process for New Product Development (NPD)
  • Introduction to CATIA V5 electrical workbench

 


2Introduction to CATIA V5 Electrical Workbench & Electrical Part Design

 

  • Customized settings for electrical environment
  • Wiring harness routing process for CATIA V5
  • CATIA V5 – electrical part design

 


3Electrical Part Design

 

  • Clip/clamps/support part definition
  • Backshell definition
  • Protective covering definition

 


4Harness Assembly & Installation – Part 1

 

  • Preparation of harness assembly
  • Creating the wire harness geometrical bundle
  • Inserting harness components into geometrical bundle
  • Positioning your inserted electrical parts
  • Connecting & disconnecting electrical components
  • Defining the wiring harness routing

 

 


5Harness Assembly & Installation – Part 2

 

  • Wiring harness routing on external references 
  • Modifying the wire harness bundle segments
  • Wire harness protective coverings
  • Use of electrical splices
  • Bundle continuity check/analysis
  • Geometrical bundle warnings
  • 3D annotation

 


6Harness Assembly & Installation – Part 3

 

  • Modifying the wire harness bundle segments
  • Modifying the branch point location
  • Deleting bundle segment
  • Bundle continuity check/analysis
  • Geometrical bundle warnings
  • 3D annotations
  • Important commands, tips, & techniques

 


7Wiring Harness Flattening

  • Wiring harness flattening workbench

  • Flattening workbench settings

  • Flattening the 3D harness assembly

  • Modify flatten assembly

  • Saving the flatten Files

  • Drawing, creation & contents

8Component Specifications & Selection Guide

  • Wiring harness component specifications & selection parameters
  • Available suppliers in market (India)

 


9Wiring Harness Routing & Packaging Basics – Session 1

 

  • Definitions
  • Routing & packaging process
  • Design criteria (generic) for wiring harness 
  • Packaging rules & best practices
  • Guidelines for battery cables routing

 


10Wiring Harness Routing & Packaging Basics – Session 2

 

  • Clearance management
  • Water ingress protection
  • Thermal protection management
  • Chaffing protection
  • Vibration protection
  • Routing on/near dynamic parts ( engine, wheel)
  • Harness bending rules (harness & battery cables)
  • Interconnection connector parking

 

 


Projects Overview

The Engine

Highlights

Route the wiring harness on the given engine and prepare to flatten view drawing in CATIA V5. Application of all packaging rules, industry best practices studied in this course shall be demonstrated in design. Apply protection coverings as required.


Car Body

Highlights

Route the wiring harness on the given car body and prepare flatten view drawing in CATIA V5. Application of all packaging rules, industry best practices studied in this course shall be demonstrated in design. Apply protection coverings as required.



BIW fixture design using CATIA V5 SYLLABUS

1Introduction to BIW-Fixture

  • Definition of BIW, jigs & fixture
  • BIW-nomenclature
  • Types of fixtures & their applications
  • BIW stations & their uses
  • Basic terminologies

2 BIW-Fixture Basics

  • Project activities
  • Different welding processes
  • 3-2-1 principle
  • Body planes

3Pre-Design Processes

  • Design methodology
  • Structuring a design tree
  • Different types of fixture units

4Units Design-1

  • Different types pin unit design
  • Different types of clamp unit design
  • Different types of rest unit design

5Units Design-2

  • Dump unit design
  • Slide unit design
  • Base unit design

6Finishing the design

  • 3D-Finish
  • Rough locators
  • Pneumatic routing
  • Valve banks & selection
  • Gun study
  • Sensors & selection

72D-Detailing Basics

  • Drawing templates
  • Angles of projection
  • Basic GD&T used in fixturing
  • Scaling & views
  • Various detailing patterns

82D-Detailing 1

  • Key sheet detailing
  • Unit detailing
  • Child parts detailing

92D-Detailing 2

  • Child parts detailing continued
  • Material selections
  • BOM preparation

10Documentations

  • Design terminologies
  • Sequence sheets
  • Clamp validations sheets
  • Ergo-sheets
  • Poka-yoke
  • Fixture process sheet
  • Cycle time study


Projects Overview

Robot Welding

Highlights

    1. Designing a Robot Welding Fixture

    Manual Welding

    Highlights

      2. Designing a Manual Welding Fixture


      Automotive Sheet Metal Design using NX CAD SYLLABUS

      1Vehicle Development Cycle

      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.

      2Basics of Automotive Body In White

      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.

       


      3Design Methodology of a Hood, Fender, Roof and Side Doors

      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.

       

      • Design requirements
      • Functional requirements
      • Regulations
      • Gap and flushness requirements
      • Safety requirements

       


      4Case study - Converting - RUECKWANDTUER INNER PANEL

      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:

       

      • Seal surface width was the same as the aluminum liftgate
      • Tailgate outer parting was maintained the same
      • Liftgate thickness was modified
      • Gap and flushness were maintained

       

       

      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.

       


      5Design of key Mechanism - Lock and Striker

      •  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.

       


      6Process and challenges with supplier manufactured parts

      • 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


      Projects Overview

      Project 1

      Highlights

       

      • In this particular project, you will be working on designing the inner panel of a hood, according to euro cap standards and make sure that the part is the manufacturer.

      • You will provide all the necessary reinforcements at the necessary regions and join the outer and inner panel using the proper joining methods.

      • You will also make sure that all the manufacturing requirements are being satisfied with all the cad parts that you design.

         


      Project 2

      Highlights

       

      • 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 to be satisfied for the deep drawing process.

         


      Project 3

      Highlights

       

      • In this particular challenge, you will develop the ditch area and roof reinforcements.

      • You will also be doing calculations to see if the roof passes the snow load criteria and heat distortion criteria.

      • The number of bow roof rails will also be calculated from the above calculation.

         


      Project 4

      Highlights

      • In this project, you will develop the inner panel of a tailgate by suggesting a tooling direction. And also make sure that the inner panel clears the draft analysis

      • You will also develop all the necessary reinforcements for the tailgate design like Hinge and Latch reinforcements and gas stay reinforcements etc. 

      • In addition to this, you will also develop the outer panel for the tailgate from the given skin data




      MOLD DESIGN USING SOLIDWORKS SYLLABUS

      1Basics of Injection Molding / SOLIDWORKS Modeling

        

      This section will have you covered in terms of 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
      • Current trend 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

      2Basics of Mold Design / SOLIDWORKS Surfacing

      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.




      3DFM and Defects

      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:

       

      • Concept of machine tonnage and learn 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.

      4Parting Surface / Mold Design Tutorial 1

       

        • In the fourth week, we will be understanding the theory behind parting surfaces. The topics that will be covered are as follows:
           
          • What is a parting surface is
          • Types of parting surfaces such as flat, stepped, angled and profiled parting surfaces
          • Example cases where we will try to understand how the selection of parting surfaces takes place
          • Matching drafts
          • Shrinkage 
          • Inserts 
           
           
          Then in the SOLIDWORKS session, we will start with our first mold design tutorial. We will be covering on 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

       

      5Sliders and Ejection System/ Mold Design Tutorial 2

      In the fifth theory session, we will be looking at the topic of sliders and ejection systems. The topics that will be covered are:

      • Need for sliders and their working. 
      • 2 general types of sliders - sliding split type molds and the angular lift pin type molds.
      • Methods of actuating the sliders such as finger cam, dog leg, cam track, spring and the hydraulic actuation
      • Concept of slider locking
      • Various types of ejector systems such as pin, sleeve, stripper, and blade ejector systems.



      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:

       

      • Creating parting lines, shut-off surface, parting surface, and mold blocks for the model.
      • Creating ejector pins for the mold.
      • Creating inserts for the mold.

      6Gates and Runners / Mold Design Tutorial 3 - Part 1

      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 are engravings used in cavity



      Then in the SOLIDWORKS session, we will be creating a mold for a door bezel model. 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.

      7Mold Design Tutorial 3 - Part 2

      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.

      8Mold Design Tutorial 4 - Part 1

      In the eighth week, we will start creating a mold for a CPU fan case model and we will learn the following topics:

       

      • Complex parting line selection that can reduce the number of sliders required for the model.
      • How to provide correct matching drafts for the model.
      • Then we will create the core-cavity surfaces for the model. After that, we will align the sprue location, select dimensions, and create the mold blocks for the CPU fan case in assembly. We will also see how to add reliefs for the core-cavity blocks.

      9Mold Design Tutorial 4 - Part 2

      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.

      10Mold Design Tutorial 5 - Part 1

      In the tenth week, we will start creating a mold for a plastic knob model and we will learn the following topics:

      • Creating the parting line, shut-off surface, and the parting surfaces for the plastic knob model. 
      • Automatic and manual shut-off surface creation.
      • Core-cavity surfaces for the plastic knob model.
      • Sprue alignment
      • Selecting dimensions and creating the mold blocks for the plastic knob in assembly. 

       

      We will also be covering some theory behind the cooling channels for a mold.

      11Mold Design tutorial 5 - Part 2

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

       

      • Creating multiple inserts for the model
      • Creating holes for fixing the inserts. 
      • Locating undercuts and creating a slider split for it
      • Complex slider creation
      • Assigning proper dimensions for the slider.

      12Mold Design Tutorial 5 - Part 3

      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 backplates.
      • 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


      Projects Overview

      Project 1

      Highlights

      For your first project on mold design, you will be working on creating a proper mold for a table fan stand. Though the table fan stand may appear to be a fairly common and simple product to manufacture, due to the presence of undercuts (explained in the course) in the model, it is actually not possible to manufacture the product using just two standard core-cavity mold blocks. In order to deal with external undercuts along with the creation of proper core-cavity mold blocks, the creation of proper additional sliders is also necessary. The process of creation of sliders will be covered in the course for other models. The students will be expected to understand the concept of sliders applied on other models covered in the course, and then apply those concepts learned to the table fan stand model. Thus, working on this project would prove to be both challenging as well as provide insight and experience on how to use sliders while creating a mold for a component.

       

       


      Geometric Dimensioning and Tolerancing using NX CAD SYLLABUS

      1Week 1: Introduction to GD&T

      In this module, you will study about GD&T and its uses. After your first class, you will be able to understand the basics such as:
      • 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

      2Week 2: Rules, Symbols, and Form Tolerances

      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

      3Week 3: Datums, Modifiers, Virtual Condition

      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

      4Week 4: Orientation Tolerance and Profile Tolerance

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

      5Week 5-6: Position Tolerance

      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

      6Week 7: Co-axiality, Symmetricity, Run-outs

      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:

      • Coaxiality
      • Symmetricity
      • Circular and total run-outs
      • Examples

      7Week 8: Understanding GD&T Drawing

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





      Projects Overview

      Valve

      Highlights

      In this project, you will be working on modeling, assembly, and drafting of a butterfly valve.

      Using NX CAD software, you will model different components of a butterfly valve. 
      • Butterfly valve body 
      • Shaft
      • Disc Plate 
      • Lever
      • Retainer 
      • Nut
      Preparation of a draft drawing with GD&T is done for all the parts modeled and an assembly of the butterfly valve is made and a draft with GD&T is prepared.

      By working on this project you will understand how to apply GD&T to the parts so that the parts can be manufactured and assembled properly with proper finish and quality.


      Flexible Course Fees

      Choose the Master’s plan that’s right for you

      Basic

      9 Months Access

      15000

      Per month for 10 months

      • Access Duration : 9 Months
      • Mode of Delivery : Online
      • Project Portfolio : Available
      • Certification : Available
      • Individual Video Support : 8/Month
      • Group Video Support : 8/Month
      • Email Support : Available
      • Forum Support : Available
      Premium

      Lifetime Access

      25000

      Per month for 10 months

      • Job Assistance : Maximum of 10 opportunities
      • Master's Assistance : Lifetime
      • Access Duration : Lifetime
      • Mode of Delivery : Online
      • Project Portfolio : Available
      • Certification : Available
      • Individual Video Support : 24x7
      • Group Video Support : 24x7
      • Email Support : Available
      • Forum Support : Available
      • Telephone Support : Available
      • Dedicated Support Engineer : Available
      • Paid Internship : 3 Months

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