suraj
Suraj Mulani

Mechanical Design Engineer with special interest in Sheet metal design & Plastic design in Automotive & Aerospace industry. NX CAD I CATIA

NX-CAD, SHEET-METAL-DESIGN, BIW-DESIGN,

About

      Mechanical design engineer with special interest in Body In White design & Sheet Metal Design in Automotive industry. Design is all about fullfilling the customer requirements in efficient way by using engineering knowledge.       I have completed my BE in Mechanical from Shivaji University, Kolhapur in 2015 with first class.       I have 2 years of experience in heavy equipment design. Can use NX, CATIA & AUTOCAD Efficiently. Good knowledge of use of GD & T in manufacturing drawing to control the process & to avoid the deviation of manufactured product from the designed one. Good knowledge of manufacturing & Machining processes. Also have working knowledge of BOM preaparation & Cost estimation.     

Projects

section modulus Optimization

   Section Modulus is the geometric property used in the design of beams or flexural members.    In general Design Elastic section modulus is used.Which is calculated by using following formula,                                              …

Base unit Theory

1) What is the Base Unit? What are the typical parts of the Base Unit? - A base unit is the unit designed to mount all the other units(Clamp unit, Pin unit, rest unit etc.) of the tool, also other parts necessary for a tool like pneumatic valve box, trunking cable path will also be mounted on to a base unit.                …

Design of backdoor panel

       Car backdoor is also known as tailgate. Basically Car parts are  made by using either steel or Aluminium depends upon the budget of car project & the premiumness of the car. Advantages of Aluminium:- Improves the strength of part. Aluminium parts are casted & we can vary…

wheel arc radius

What is wheel arch? An arch-shaped cavity in the body of a vehicle, which houses a wheel.It is designed in to protect road users. Different countries have their different standards & regulations for wheel arch. We are considering the europian standards to check wheather the given arch will pass or not. Preparation…

Flattening & Forming

     In some cases we have to work on the models with some advanced sheet metal operations like joggle, the file format is also dumb or neutral CAD file & need some features addition, Then what should we do?     In this project have worked on the same case mentioned above. Have worked…

Fender design

Purpose-     To design the Drip Area, Sillmount area, bumper mount region and A-pillar mount Region. Fender Design- Primary pusrpose of fender is to avoid sand, mud rock, liquid & other particles to be thrown in air due to rotation of the wheel Fender avoids motion of the rocks which can be hit to the…

BIW Fixture Design Methodologies Theory

1) What is Design Methodology? - Design methodologies is one of the pre design process which is the steps followed during the concept designing phases in fixture design.               fig-shows the various categories in Design methodologies - Categories are…

catia acronym

computer-aided three-dimensional interactive application

3D Finish Theory

1) What do you understand by the 3D finish process? - 3D finish is the process where design is being completely finish & to be ready for final simulation & 2D detailing. -                        - While…

odd shaped enclosure-workflow

            In some cases we can't directly go to the sheet metal design due to the required shape of the part. We cannot design that shape in sheet metal environment. So what should we do to achieve the required shape?            In this kind…

Sheet metal Box

     Sheet metal box model is shown in the following figures. Fig-1 shows all the parts of the box assembly. Lid is the opening & closing part which is attached to the box via link as shown in fig-1.     Some features Dimple & beads are added to the side & to the bottom of…

Documentations

purpose- Create a BOM, the Hardware list and the Process Sheet for the complete Fixture assembly.   *What is BOM? - A bill of materials (BOM) is an extensive list of raw materials, components, and assemblies required to construct, manufacture or repair a product or service. A bill of materials usually appears in a…

BIW Fixture Basics Theory-1

1) What is BIW & define its parts?       Body in white (BIW) refers to the stage in the automobile manufacturing in which a car body's components have been joined together, using one or a combination of different techniques: welding (spot, MIG/MAG), riveting, clinching, bonding, laser brazing…

BIW Fixture Basics Theory-II

1)What is the process of project execution activity? -                            Fig-Shows the project activities - Project activities are the tasks from the start to end of the project. There…

Creating bends

          Bending of sheet metal is a common and vital process in manufacturing industry. Sheet metal bending is the plastic deformation of the work over an axis, creating a change in the part's geometry. Similar to other metal forming processes, bending changes the shape of…

Base unit Design

 Purpose-    To Design a Base Unit with rough locators & all weldments for the given Car Panel.    Note:- To include minimum of 1 Rectractable Pin Unit.   Answer-    First of we should kno,    1) What is Base unit ?    - A base unit is the unit designed…

Hood design

Data to be used: Hood Thickness Information Outer Panel Thickness = 0.75mm Inner Panel Thickness = 0.75mm Reinforcement Thickness = 1.5mm Master sketch:-     Hood is the cover for engine compartment. It consist of Outer panel & Inner panel,with lock & Stiker assembly  for the locking purpose.It…

sheet metal casing

      Sheet Metal casing is as shown in fig-1. Some features like dimple & Bead are added to increse the strength of the casing. Fig-2 shows the flat pattern of the casing.                                                   …

clamp unit sheets

purpose- 1) Draft a different Clamp Units with all child parts for the Complete Fixture assembly. 2) Draft a Retractable Pin Unit drawings with all child parts for the complete Fixture assemly.

Roof design

       Rollover crashes are usually very destructive events.Vehicle damage often includes deformation of the roof and its supporting structures. Head and neck injuries are common, and associated with roof deformation. Strengthening of the roof is suggested as an appropriate counter measure…

Pin units design

Purpose- Design 2 different types of Fix pin unit & Retractable pin unit - pin unit is a unit designed to locate the car panel using pin. - Pin unit consist of riser, blade, block, shims or spacer, pin retainer & pin. - pin unit is the part of the 3-2-1 locating principle of fixture design. It restricts 6 degrees…

3D Finish design

Purpose-     Perform 3D finish on the Assembly design & Write a Detailed Report describing the process (what changes are made on the design) and attach relevant images. Answer - - 3D finish is the process where design is being completely finish & to be ready for final simulation & 2D detailing…

2D Detailing & GD & T theory

1) What are the Drawing templates? Ans- -A drawing template is one of the main components to any assembly or part drawing. A drawing template allows you to convey all information about a part or assembly in a clean and organized manner. The key features of a drawing template are simplicity and clarity. - Drawing templates…

Benchmarking

Benchmark with present available cars in market for the following case.     1) Mr . D.S. Pughazhyendhii is a married man who lives in Bangalore which is a highly crowded city.His Family comprises of five members including his wife, five-year-old boy, his father and mother. He visits his native place Madurai…

2D to 3D conversion part-2

     As mentioned in part-1 of 2D to 3D conversion the imagination plays very important role in design engineers life. This project help to develope this imagination power.    in this project of 2D to 3D conversion part-2,I  have worked on the given 2D drawing as shown in fig-1. …

2D to 3D conversion-part 1

        Imagination plays very important role in design engineers life. Every should be able to imagine the 3D geometry from given 2D drawing. If your imagination skill is good enough then you can imagine the model geometry quite well.        in this project…

Underbody coating

In Indian road conditions, a cars underbody is most prone to corrosion. 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. -Here are…

Dimple using solid punch

     Dimple using solid punch model is shown in fig. Dimple is used to give some strength to the part. The flat portion of the part posses less strength & rigidity, so there are higher chances of failure of the part. The dimple adds strength & rigidity to the part & reduces the chances of…

Project 2

Purpose-    1)Initiate a concept of Fixture design.    2) Perform 3D finish on the Assembly design    3) Perform 2D finish with output documentation    4) Write a Detailed Report describing the process (what changes are made on the design) and attach relevant images. Answer -  …

Course Certificates

Advanced Sheet Metal Design using NXCAD

Completion Certificate UID : EniXP3j5vmX1qgoF

Automotive Sheet Metal Design using Siemens NX CAD / CATIA V5

Completion Certificate UID : vLumURtXmtXb5eMh

Automotive BIW Fixture Design using CATIA V5

Completion Certificate UID : kb7hi5mfopg29x0n

Participation Certificates

Insight into GD&T

Workshop Certificate UID : ka1ljc7h4m

Bootcamp Certificates

Fundamentals of Automotive Plastics Design

Bootcamp Certificate UID : g8jsatk3iz

Fundamentals of Automotive Plastics Design

Bootcamp Certificate UID : vykg876izr