Benchmarking When an automotive company decides to launch a new model in the market, there are various steps that take place before the car is actually launched. The first and foremost for it consists of studying the existing market and pin pointing the trends. This study is what we call benchmarking. Wherein we decide…

Underbody Coating of Automobiles Underbody coating is the spraying of the underbody of the automobile with a dense coating, which is usually rubber based. The underbody of the automobile is always exposed to the ground and environment and is usually prone to chipping due to small rocks hitting the surface or splashed by…

Designing of Hood Inner and Outer Panel The hood is a panel that is used to cover the engine compartment from various environmental effects like water and corrosion as well as a styling item. It allows access to the engine compartment needed in case of repairs or checking on various fluid levels. It also adds to the overall…

Section Modulus and Optimization.   Section modulus of a cross section is the quantifying property of the geometry. It is the ratio of second order of moment of inertia to the distance between the neutral axis to its farthest point. Higher the value of section modulus better is the stiffness. Hence, it is more resistant…

Fender Design Fender is a side closing component, which is used to prevent things such as water, small rocks, and mud from hitting the engine compartment. The fender covers all four wheels of the vehicle and is classified into front fender and rear fender. However, the rear fender is integrated together with the body side…

Design of Roof Roof of a car is the potion of the automobile that sits above the passenger protecting the vehicle from outside elements like wind, rain, sun, and other external elements. Newer versions also come with glass roof or sun roof. Roof consists of various reinforcements along with the external styling surface.…

Design of back door.   Backdoor of a vehicle is a very important part from passenger safety’s point of view. Hatchback have the backdoor connected to the roof where as in sedans it is hinged below the window level. It consists of inner panel and outer panel. The outer panel can be made of two or three parts, but there…

EDS (Electrical Distribution System) Electrical Distribution system deals with power distribution to the various components in an electrical system. It deals with Physical and Logical Architecture, Schematic Development along with wiring harness design, wiring harness component design of the same. Logical Architecture…

Defining Component as Support/Back-shell and Creating Protection Coverings. A) Defining a P-Clamp as Support. Clips and clamps are used to securely clamp the harness to various parts of the vehicles. It is also made of plastic and has mounting features provided.   In order to define a component as support following…

Aim: To electrically define the components used in routing the harness according to the given diagram. Adding protective covering to the same with 30mm extremity from connectors. Step 1: Defining the connectors as electrical components. Define the bundle entry point and connector connection point of the components. Given…

Aim: Route the harness and check for the following: Check the bundle Continuity.  Add annotation to all connectors.  Check for the bundle warning.  Generate CAT.part of harness assembly and convert is in. igs format. Harness Layout: Given Step 1: Download the files required for harnessing and define all of them as electrical…

Aim: To create a harness assembly as instructed and flattening it, along with creating 2D drawing for the same. Step 1: Electrically defining the connectors needed for harnessing.   DT06-6S DT06-4S   DT06-2S DT06-08SA   Step 2:  Positioning the connectors at appropriate places and defining the assembly as a geometrical…

Aim:  Route wiring harness for given engine. Apply all the packaging rules to the same and add protection covering where required.   Introduction             The main objective of this project is to route the wiring harness of a V16 engine using the appropriate design criteria having the required clearance, using the right…

Aim: To route the harness for given tailgate using proper supports wherever required using industry best practices and adding protective covering wherever necessary.   Introduction             The main objective of this project is to route the wiring harness of…

What is BIW? Define its parts.             BIW is the stage where all the parts of the body of a car are joined together using various techniques and is the base for any further processing. BIW is the term given to the assembled body on which process like painting…

 Fixture Basics design What is the process of project execution activity? Execution starts from receiving the RFQ to handling over the fixture setup. There are a lot of steps which are included in between, which are as follows: Request for Quotation (RFQ): Before a process can start, the request for specifications…

What is design methodologies? Design methodology is the process followed to make the design process smooth and easy to understand by all. The steps followed in design methodology includes things like structuring the tree in a particular way, naming the tree in a particular way for it to be easy to understand for any person…

Pin Unit Challenge   Aim: To design 4 pin units each having different types of pins, risers and block, retractable and fixed. Introduction A pin unit generally consists of pin, retainer, block, riser, spacer and shims along with bought out parts like cylinders for retractable pins, bolts for fastening of the parts…

Clamp and Rest Unit Aim: To design clamp and rest units with different types of blades, clamps and risers for the given car panel. Designing 3 clamp units and 2 rest units. Types of Units designed: 1) Rest Unit: It is the simplest unit to design and has the minimum number of parts. It is used to rest the component. No…

Aim: Design 3 different types of clamp units and a clamp-pin unit. Clamp Unit Basics: 3-2-1 Principle: This principle is used for locking the 6 degrees of freedom of the component. A resting unit locks 3 degrees of freedom. The up and down movement and 2 rotational degrees of freedom. For locking all 6 degrees of freedom,…

1) What is a Base Unit? What are the components of a base unit? Base unit holds all other units and tools necessary for a fixture assembly. Units like pin unit, clamp unit, etc. are loaded on the base unit. The individual parts of the base unit are welded together. The base unit is designed depending on the requirement…

Base Unit and Fixture Unit Aim: To design base unit for a fixture unit. Base Unit Introduction: Base unit holds all other units and tools necessary for a fixture assembly. Units like pin unit, clamp unit, etc. are loaded on the base unit. The individual parts of the base unit are welded together. The base unit is designed…

1) What do you understand by the 3D finishing process? It is the finalizing of the model and one of the last stages before drafting. The size of the holes, there positioning and feasibility is checked during this stage. All the parts or surfaces that needs to be machined are shown clearly for easy understanding. The product…

Aim: To perform 3D finishing on the fixture assembly and adding rough locators wherever necessary. Introduction: At this stage the assembly is checked at various points for correct positioning. The concentricity of all the holes is checked. The assembly is checked for clashing with weld gun, if a clash is detected, the…

1. What are drawing templates?   Compared to conveying data in verbal or written form, symbols and drawing provide information in a better and more understandable way minimizing errors caused by miscommunications or misunderstandings. Drawing templates are standards decided by the client.  Drawing templates are…

Aim: To draft Fixture Assembly with key sheet and layout sheet. Drafting of Base Unit and Fixed Pin Unit.   Drafting of Fixture Assembly:       Drafting of Base Unit:           Drafting of Fixed Pin Unit:         Conclusion: Thus, Detailing of the given units…

Aim: To draft all the Clamp units and Pin units of Fixture assembly.   Pin Units:   Fixed Pin Unit:   Retractable Pin Unit:     Clamp Units:   Clamp Unit 1:     Clamp Unit 2:     Clamp Unit 3:     Clamp Unit 4:     Clamp Unit 5:   Conclusion: Drafting…

Aim: To create Bill of Materials (BOM) an Hardware list (BOP) of the fixture assembly.     Conclusion: BOM and BOP for the Fixture Assembly is created.  

Aim: To add sliders to the core and cavity created for the given model. Sliders: To create the sliders, the profile is first used to split the body and cut short to a required length enough to fit the finger cam pin to fit. The back of the slider should have a tappering figure of 30 degree to fit easily into the cavity…

Aim: To create sliders for the undercuts and create inserts fro the CPU fancase where ever required.   1. Sliders To create the first slider for the circular undercut, first the core body is split and required profile is created for the same. Once the body fro slider is ready, additional space is cut from the core…

Aim: To add Ejector system to the mold assembly complete with back plates and pins. Creating runner gate system and provinding cooling channels.   1. Ejector System: To eject the plastic component out of the COre blcok, ejectors are required. As the ejectors are on a slope D type ejectors are needed. Ejectors are…

Aim: To make mold blocks for the given component and add sliders and ejectors where ever necassary.   1. Core and Cavity Surface  To create the core and cavity surfaces, first the component is scaled to compensate for the shrinkage. Next, parting line is created and the surfaces needed to be shut-off are closed to make…

Aim: To create Mold assembly with sliders, ejector system, air vents for the given component.    1. Core and Cavity Surface: To create the surface, first the parting line is decided at the bottom of the component after scaling of the prdoduct is done. Next, using shut-off surface command the open profiles are first closed.…