Title : Modelling and Assembling a Chopper Objective : To understand the application of basic principles and features of Solidworks. Introduction : This project provides an introductory view for using Solidworks to model an American Chopper part by part and render the final assembly of all parts into presentation level…

Title : Modelling Sunseeker Predator Yatch Obective : To design and assemble a complete model of the Sunseeker Predator yatch Introduction : This project involves the application of Solidworks for the modelling of a Yatch, honing the skills accrued during the previous project of the American Chopper. The use of surfaces…

Report  Draft analysis and Closed Surface were designed using Class A surface as input. The Draft angle was kept at 3 degrees and tested on the surface with respect o the tooling axis before designing the Class B and Class C surfaces. The tooling axis was designed in the Z-Axis after analyzing the Class A surface…

Report   The tooling axis was created using sketches of lines based on the geometry of the Class A surface. The A surface has three vertical wall faces which are almost vertical to the Z axis. In order to select the Z axis as the general direction of tooling, based on the geometry of class A, the tooling axis must…

Report   The tooling axis for this part was determined to be in the general direction of the Z axis based on the geometry of the class A surface. ny line on the Z axis is at an angle greater than 3 degrees from all four walls and the auxiliary surfaces of the coin holder while the base is perpendicular to it. Therefore…

Report :  The tooling axis was selected based on the surface geometry when viewed from the different axes. When viewing through the x-axis the features of the surface can be cleared without hassle, so a draft analysis was done with a line parallel to the x-axis as the tooling axis. The resulting analysis helped finalize…

  Class A and Class C :   Class A initial Class B  Dog House :  The draft provided through the Master sections is inadequate.  Please note that the Master section and given input for dog house design do not match. It is either incomplete or unclear.    

 Report :  The given input draft drawings were used as a reference to create the individual solid bodies. Each separate solid body was made with boolean operations to devise a final design. The individual bodies were then imported into the product in Catia where they were assembled. The assembly process is to…

Report Benchmarking for a customer (Mr. D.S. Pughazhyendhii) Problem Definition Benchmark with presently available cars in the market for the following case. Mr. D.S. Pughazhyendhii is a married man who lives in Bangalore which is a highly crowded city. His Family comprises five members including his wife, a five-year-old…

Modern automotive coating methods consist of five main steps. They include the following: Pretreatment: removes and cleans excess metal and forms an appropriate surface structure. Enabling bonding of a corrosion protection layer. The next step is electrodeposition (ED) of the anti-corrosion or rust prevention layer. A…

Report: Hood Design Input: Outer panel (A surface) Problem Definition: Design a complete hood of an automobile given a master section, and hemming data with inner and outer panel thicknesses up to 0.75 mm.  Design Study: Hood: The hood (American English) or bonnet (Commonwealth English) is the hinged cover over…

What is Section Modulus? Section modulus is a geometric property for a given cross-section used in the design of beams or flexural members. Section modulus is defined as S = I / y, where I is the second moment of area and y is the distance from the neutral axis to…

Fender is the term for the part of an automobile, motorcycle, or other vehicle body that frames a wheel well. Its purpose is to keep mud, rocks, and other road debris from being thrown around by the tires. In other words, the fender is a housing for the wheels that keeps road debris contained. If there was nothing covering…

Report   There are two main types of fenders: full-bumper type and half-bumper type. The full-bumper type fender is used when the front end of the bumper is integrated with the front bumper and headlamp casing. Half-bumper type fender is popular and used when the headlamp casing is independent and housed between the…

Objective: To design a roof for an automobile with given master sections and satisfy the roof curvature analysis for Heat distortion and Snow Load criteria. Design Considerations: Headroom clearance Bow roof position Heat distortion and Snow load criteria Draft analysis Input: Styling: Final Design: Roof Outer Panel with…

Objective: Design of Backdoor with input outer styling. Introduction: The backdoor is the part of a vehicle that is a closure commodity at the rear of the BiW. This door usually encloses a boot space (luggage area) or acts as a rear entry depending on the type and design of the car. The material selected for this component…

The definition of connectors follows a stepped procedure, as follows: Defining the geometrical parameters required like points and axis sytems. Defining the the part as a connector in the electrical part workbench. Defining Bundle connection point. Defining the connector connection point. Defining the cavity connection…

Report:   Clips: These are attachment (support) features that provide firm fixes to the wiring harness to arrest movements. They have two entry and exit points, which must be defined inside CATIA. Corrugated Tubes: These are used as covering material for the wiring harness to provide protection and/or aesthetics. Conclusion:…

Report   Problem Definition: To design a wiring harness route according to the layout below: Conclusions: The desired wiring harness route was designed using the required connectors which were electrically defined after being downloaded from the internet. The protective covering of COT was terminated 30 mm before…

Conclusions: The required circuits were designed and connected after electrically defining the connector with the required attributes. The connectivity and bindle warning associated with harnesses A and B : A- B-   The harnesses A and B after being electrically connected via the connectors:  

Conclusions: The wiring harness flattening was performed and a drawing was made where single and double lines were used for representing the bundle segments and protective covering respectively.

Objective: To provide a concept for a wiring harness for a given tailgate of a car. Input: CAD data of the backdoor of a car.      Design considerations and packaging rules: Easy manufacturing, installation, removal, and maintenance of the product. Routing shall be designed to minimize chaffing and handling…

Objective: Application of packaging rules and Industry Best Practices for Wiring Harness routing for a given engine. Theory: The given engine will have the following requirements: 16 connectors, 8 on each side for each cylinder. A 4-pole connector is selected for this as it is most commonly used for fuel injector connections.…

The assembly of the Butterfly valve-   The individual parts that have been designed must be assembled into the final shape of the valve with the necessary assembly constraints. The final assembly: The drawing with Geometric Dimensioning and Tolerancing:        

Design of Side door Trim  Aim: Creating a CAD model of a side door trim panel from a given class A surface. Introduction: The product life cycle in the automotive industry is roughly categorized into the following steps: Concept sketch Styling class A Feasibility check Concept validation  New product design Product…