Aim: To create a Base Bracket Plastic Component through a given Class A Surface and perform Draft Analysis on the final plastic component. Objectives:  Creation of Tooling Axis. Creation of Class B and Class C surface. Creating a solid part out of surface modelling. Draft Analysis of Class A surface and final…

Aim The aim of this project is to develop the product design of the switch bezel with the help of the class A surface following the OEM standards. Introduction Class A Class A surface is the term mainly used in automotive design industry. It describes the final production surface data for the aesthetic parts of the…

AIM The aim of this project is to develop the product design of the COIN HOLDER with the help of the class A surface following the OEM standards. OBJECTIVE To Create the Coin Holder Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting…

BUMPER DESIGN :- what is bumper? A device for absorbing shock or preventing damage (as in collision). which material is used for Bumper? why? -  Polycarbonate (PC) & Acrylonitrile Butadiene Styrenel (ABS) thermoset platice are used to manufacture the bumper. But Mostly they use Acrylonitrile Butadiene Styrenel…

AIM : Creating the Core and Cavity blocks for the Switch Bezel Design. Core : The core is the male part which forms the internal shape of molding, the upper half of the mold where the toolwhere the plastic part is injected from is called core. Cavity : The cavity is the female part which forms the external…

INTRODUCTION OF DOOR TRIM LOWER   Next to the dashboard, the door trims are the interior parts that contain the most controls and decorative parts. As such, there is a necessity for balancing gap between parts, as well as an overall sense of unity between the numerous parts.   Materials used for Door Trim Lower…

AIM : Create the rib and Screw boss for the Drill Handle considering the design rules.  Tooling axis & Draft Analysis: The direction in which the mold or core and cavity opens is the tooling axis.  To create the tooling axis, I extracted a surface from class A and created a point in the middle of…

AIM: Create the Dog House for the Door Trim considering the design rules. Consider the thickness of the part to be 2.5 mm. "C" is where the doghouse contacts the backside of the surface.  Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock…

DOOR TRIM LOWER Aim: To Create the Door trim lower with Engineering Features component through the given Class-A surface. Objectives: Creation of Tooling axis with appropriate draft angle. Creation of other surfaces (eg, B and C surfaces) for creating a solid component. Perform Draft analysis on Class A surface and Solid…

DESIGNING A PILLAR USING MASTER SECTION OBJECTIVES To improvise the Class A surface by resolving bad patches and adding flanges to it.  To create A pillar solid model with the help of  improvised class A surface. To create B side features for the A Pillar using the master section given to us as an input. To create main…

STRESS CONCENTRATION IN A PLATE WITH HOLE OBJECTIVE 1. To design a plate with hole for the following cases, Case(1): Length=300mm, height=120mm, thickness=30mm, circular hole at the center with diameter=60mm. Case(2): The dimensions are similar to case 1, but additional two smaller holes of diameter=30mm away from center.…

AIM: To design the car door inner panel with reference to given Class-A surface by using given mastersection, creating attachment features and performing draft analysis to check the manufacturing feasibility of the component by using software CATIA V5. Objective: Analysing the class A  and performing necessary modification…

ASSEMBLE OF BUTTERFLY VALVE DRAFTING 3-2-1 Principle of Location The 3-2-1 principle of location (six point location principle) is used to constrain the movement of workpiece along the three axes XX, YY, and ZZ. This is achieved by providing six locating points, 3 pins in base plate, 2 pins in vertical plane and 1 pin…

BENCHMARKING Benchmarking is a process of measuring the performance of a company’s products, services, or processes against those of another business considered to be the best in the industry, “best in class.” The point of benchmarking is to identify internal opportunities for improvement. By studying companies with superior…

What is Underbody Coating? -Underbody coating provides long term protection from corrosion to car’s underbody. It also protects parts like internal body panels, frame rails and other inner cavities that are not physically accessible but are prone to corrosion. Benefits1) Minimizes Sound: It minimizes the sound from underneath…

AIM: To design the car hood and understand the mechanism behind the design of hood, then development& its safety features as per the design consideration. The following task is performed: Design Outer Panel with the Hem. Develop the Inner Panel. Develop all the Necessary Reinforcements. Mirror and position the Hinge…

Aim: To find the section modulus of the hood and optimization to improve the overall section modulus.   Objective: Use the section from your Hood design and calculate the section modulus using the formula S= I/y.   Section Modulus: The section modulus (S) is geometry property of the cross section used for designing beams…

AIM - Design 10 kW permanent magnet synchronous motor with Ansys RMxprt and analyse its performance in terms of torque, speed, current density and flux density with Maxwell 2D. OBJECTIVE-1. Motor power estimation Motor sizing estimation motor design in multiphysics activity and different application demands Rmexpert…

Fender Fender is a part of an automobile, motorcycle or other vehicle body that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other road spray from being thrown into the air by the rotating tire. Fenders are…

Aim The aim of this project is to simulate the flow inside a Battery Thermal Management System Objectives The main objectives are as follows      • Excel Calculator for Volumetric heat generation source Run the case for different mesh sizes-12.8.6 and 4 mm. Effect of element length on accuracy of results.   Setup  1. Solver-Density…

Aim: To design the Front Fender using CATIA V5. Objective: Design the Fender with the necessary Mounting areas given below: Drip area A-Pillar mount Sill mount Bumper mount Baffle mount DESIGN OF A CAR FENDER Fender is  the part of an automobile, motor cycle or other vehicle body that frames a wheel well…

Title- Design of Roof Objectives- For the Given Roof styling, Develop the essential flanges and reinforcements, provide appropriate dimension and check for Draft analysis and also submit your section modulus report on the 0-Y section. Start with the creation of a roof ditch area the tool opening angle is only 3 degrees.…

DESIGN OF BACKDOOR Aim: Designing the Backdoor by Using the provided styling surface to come up with a back door design and  using appropriate design methodologies and make the necessary reinforcements and embosses. What is a back door? A door is a hinged part which is used for entry and exit of the vehicles. Back doors…

WIRING HARNESS DESIGN IN CATIA V5 AIM        To Download following connectors & Connector clip cad data from given link & define it as Electrical Connector using Electrical Part design Workbench. Define all the necessary properties to Connectors & Clip. Deutsch DT06 – 08SA…

  AIM :  Download following cad data & define it as Electrical support using Electrical Part design Workbench. Define all the necessary properties. Create Following Corrugated tubes & Add them in Catalogue under “Slit COT” family.       Name ID (mm) OD (mm) Thickness (mm) 15mm…

AIM: To check for the geometrical errors and mesh with the given element Quality criteria. After meshing the component the thickness has to be assigned for the given component. GIVEN DATA: The given data are the inputs to work. Here the given data are, CAD model. Quality criteria.   CAD MODEL: Here the given…

WIRE HARNESS ROUTING - WEEK 4 AIM: Route the following harness layout in Electrical workbench. Make assumption for harness bundle diameters. Use Following connectors as shown in layout diagram. Add protective covering on all branches connected to DT06-2S & DT06-4S connectors. Keep end extremity at 30mm (from connectors…

BENCHMARKING Benchmarking is a process of measuring the performance of a company’s products, services, or processes against those of another business considered to be the best in the industry, “best in class.” The point of benchmarking is to identify internal opportunities for improvement. By studying companies with superior…

What is Underbody Coating? -Underbody coating provides long term protection from corrosion to car’s underbody. It also protects parts like internal body panels, frame rails and other inner cavities that are not physically accessible but are prone to corrosion. Benefits1) Minimizes Sound: It minimizes the sound from underneath…

AIM: To design the car hood and understand the mechanism behind the design of hood, then development& its safety features as per the design consideration. The following task is performed: Design Outer Panel with the Hem. Develop the Inner Panel. Develop all the Necessary Reinforcements. Mirror and position the Hinge &…

Aim: To find the section modulus of the hood and optimization to improve the overall section modulus.   Objective: Use the section from your Hood design and calculate the section modulus using the formula S= I/y.   Section Modulus: The section modulus (S) is geometry property of the cross section used for designing beams…

Fender Fender is a part of an automobile, motorcycle or other vehicle body that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other road spray from being thrown into the air by the rotating tire. Fenders are typically rigid and can be damaged by contact with…

Aim: To design the Front Fender using CATIA V5. Objective: Design the Fender with the necessary Mounting areas given below: Drip area A-Pillar mount Sill mount Bumper mount Baffle mount DESIGN OF A CAR FENDER Fender is  the part of an automobile, motor cycle or other vehicle body that frames a wheel well (the fender underside).…

Title- Design of Roof Objectives- For the Given Roof styling, Develop the essential flanges and reinforcements, provide appropriate dimension and check for Draft analysis and also submit your section modulus report on the 0-Y section. Start with the creation of a roof ditch area the tool opening angle is only 3 degrees.…

DESIGN OF BACKDOOR Aim: Designing the Backdoor by Using the provided styling surface to come up with a back door design and  using appropriate design methodologies and make the necessary reinforcements and embosses. What is a back door? A door is a hinged part which is used for entry and exit of the vehicles. Back doors…

Aim : Route the Given harness layout in Electrical workbench & Apply the Conditions. Ojectives : Check the bundle Continuity. Add snap of result in submission Add annotation to all connectors. Make an assumptions for annotations like connect 1 , 2 etc Check for the bundle warning. Add snap. Generate CAT.part of harness…

AIM: TO FLATTEN THE WIRING HARNESS AND DRAFT THE WIRING HARNESS ASSEMBLY. Add protective covering on all branches connected to DT06-2S & DT06-4S connectors. Keep end extremity at 30mm (from connectors end)  Download connector 3D data from www.te.com DT06-4S DT06-6S DT06-2S DT06-08SA DEFINIG ELECTRIC PARAMETER…

AIM: To route the wiring harness for the given engine. Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required. 1.INTRODUCTION The automotive wiring harness is referred to as the central nervous system in the vehicle. It…

AIM: To route the wiring harness for the given Tailgate. Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required. OBJECTIVE The objective of this project is to route the wiring harness and prepare flatten-view drawing for…

Objective:  To mesh the components of Cross Car Beam to qualify the given quality criteria Assemble the CCB by using appropriate connections Quality criteria:  S.No  Quality Criteria  Value  1 Target/Average length   5 2 Minimum Length  3 3 Maximum Length  7 4 Aspect  3…

AIM: To check for the geometrical errors and mesh with the given element Quality criteria. After meshing the component the thickness has to be assigned for the given component. NOTE: In this challenge, there will be some off elements found in the chamfer region which cant be removed. It is acceptable as it is been found…

AIM: To perform FE modelling of an Automotive IP trim component by considering the given element Quality criteria. KEYWORDS: Mid-surface Extraction, Shell Meshing. OBJECTIVE:   Introduction to shell meshing i.e. 2D meshing Geometry check & Topological error clean up  Mid surface generation  Meshing…

Meshing of Floor Panel Follow the below-mentioned quality criteria, mesh the component given below, and assign thickness: Target Element Length = 5 Units S.N Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3 Warping 15 4 Taper      0.5 5 Min. Length 2 Units 6 Max. Length 8 Units 7 Min angle Quad 45 8 Max angle…

  OBJECTIVE To mesh the given rearview mirror component in both 2D and 3D, after checking the model for geometrical errors and fixing them. Also, to ensure the generated mesh follows the given quality criteria.   QUALITY CRITERIA Shell Elements S.No  Quality Criteria  Value  1 Target/Average length  …

AIM: To Mesh the Given component with the Size of 5 Units & to Create 1D elements on the following component with given cross-section and DOF. GIVEN DATA: a. Rod element:- Translational DOF should be Constrained with RBE2 link Cross-Section: BOX- Dimension a= 12 mm              …

Preprocessing of Hood Model Using Hypermesh   Objective : Make proper geometric clean up on the surfaces. To extarct a proper mid surface from the parent components. Maintain Proper mesh flow with less tria concentration. To achieve exact quality criteria as given in the question. Mesh the component properly with…

Manual Midsurfacing & Meshing of Car Backdoor   Objective : Make a proper geometric clean up on the surfaces if there is any damaged surfaces. To extract a proper mid surface from the parent components manually. Maintain a Proper mesh flow with less tria concentration. To achieve exact quality criteria as given…

Deploying Connectors for a Rear Door of a Car   Aim - To Deploy a appropriate connectors for a Rear Door of a Car. Objective - Creating a property id's for door hinges and deploy a bolt connectors. Creating RBE2 1D Elements for bolt joints. Creating RBE3-CBUSH-RBE3 element for the weather strips. Creating RBE3-HEXA-RBE3…

Creation of 1D Connector's Challenge.   Objective - To mesh the given frame assembly with 2D element's with a target element size of 5 units. Use different types of Connection techniques and Deploy connector's to the component's as per given below. How to debug the connector's,If they are failing. Right_Rail_2 & Front_truss_1…

Meshing of Rear Wheel Holder [Spare Wheel Floor Panel]   Aim - To perform preprocessing on the given Rear Wheel Holder [Spare Wheel Floor Panel] Sheet Metal component using hypermesh preprocessing software.   Objective - To generate the mid surface manually and do a geometry clean up on the component. To generate a mesh…

The meshing of Car Side Door [Inner Panel] Aim -To perform preprocessing on the given car side door [Inner Panel] plastic component using hypermesh preprocessing software. Objective -To generate the mid surface manually and do a geometry clean up on the component.To generate a mesh and to get a proper mesh flow on the…

 CAR TAIL LIGHT LENS                              A car headlamp lens is a protective covering that is mounted on the front of a car's headlamp assembly. The lens serves as a protective barrier against any debris, dust, or elements that could…

B-PILLAR The B-Pillar Is The Central Pillar Of The Car. This Pillar Is Actually a Sheet Metal Part Which Is Welded In The Biw Of The Car. The B-Pillar Trim Is Attached To The B-Pillar And Improves The Aesthetic Look Of The Car. Mostly The Trims Are Manufactured By The Injection Molding Process. The Design Of The B-Pillar…

MODEL 1 - 2D to 3D Conversion method. AIM: To Create a Teramesh for Housing component with the following quality criteria by following TetraMesh Generation Method: 2D to 3D Conversion. GIVEN DATA: The given data are the inputs to work. Here the given data are, CAD model. Quality criteria.  1.Cad model:                …

Define tooling direction   2) Create tooling direction for Class A with 10 deg draft ( draft in command should be 10 deg) and show the draft analysis.   3) Create B surface of the given lens in surface modeling (not in part), with a 4 mm thickness.   4) Write the definition of the Parting line.                        …

2D Meshing   Aim - To perform pre processing on the given three models according to the given requirements using hypermesh pre processing software. Objective - To do geometric clean up on the given three models. To extract a mid surface for all the given three models. Defeaturing the edge fillets. To do geometric clean…

  Aim - To calculate the values and to edit the engine file with that values. To perform volume mesh on the given components housing model and arm bracket model. Objective - To calculate the speed of sound in steel rail. To calculate the time for sound to travel over length of the rail. To edit the engine file. To perform…

2D Element Formulation   Aim- To run the simulation for the given component with and without changing the recommended element parameters using a radioss solver. Objective- To change the run time to 55 ms and to change the number of animation steps to 60. To run the base simulation with default element parameters. To check…

RADIOSS Material Laws    Aim - To run the simualtion for the plate and rigid ball by using Jhonson Cook Material and Elasto Plastic Material with Brittle Failure as per the cases given in the question by using Radioss solver.  Objective - Run the simulation for all the 7 cases as…

RADIOSS Interfaces & Study of Effect of Notches Aim -To run the crash tube model by using differnt types of contact interfaces.Mesh the given crash tube model with 6mm size.Objective -Run the crash tube model with and without changing the parameters.Remove the notches from the crash tube model,Remove the boundary…

Frontal Crash Simulation    Aim - To run a simulation for the frontal crash [BIW] and to obtain a results in the post processing.   Objective - To check the unit system in the solver. To create an appropriate interface ,friction 0.2 and recommended parameters. To check for the penetrations and…

Side Pole Crash Simulation  Aim : To run a simulation for the Neon Side Pole Crash and to obtain the results in the post processing. Objective :   To check the unit system in the solver. To create an appropriate interface with friction 0.2 and recommended parameters. To check for the penetrations and intersections…

Roof Crash Simulation    Aim - To run the roof crash simulation on the neon car model and plot the graphs for the neon car model in post processing.   Objective - To translate the impactor to the desired location as per the question. To create a Type 7 contact interface between impactor and car. To create…