STEP1:-                GIVEN MODEL IS HAVING UNDERCUTS, INORDER TO DEAL WITH IT SLIDERS WILL BE NEEDED. SLIDERS WILL BE NEEDED FOR THE SLOTS ON BOTH SIDES . SO START WITH CAVITY BLOCK . FROM THE CAVITY BLOCK WE HAVE MAKE SLIDERS WITH USE OF SPLIT COMMAND.…

STEP-1:- UNDERSTANDING THE MODEL & DECIDE THE TOOLING DIRECTION. THEN SELECT DRAFT ANALYSIS OPTION HERE SELECT TOOLING DIRECTION & GIVE DRAFT ANGLE AS 0.5°. SINCE THE PART HAVE SOME UNDERCUTS, IT NEEDS SLIDERS (DO DRAFT ANALYSIS FOR SLIDERS ALSO). CAVITY SIDE SHOWN AS GREEN SURFACE        …

CREATION OF CORE & CAVITY BLOCK COMPLETED IN PREVIOUS CHALLANGE ITSELF. HERE WE START FROM CREATION OF SLIDERS FOR UNDERCUTS.   STEP:1 MAKE SOME SKETCH IN CORE BLOCK TO SPLIT INTO TWO BODIES  USE SPLIT COMMAND  STEP:2 NOW USE EXTRUDE COMMAND , TO MAKE SURE HOLE PROFILE MADE IN SLIDER BODY.   STEP:3…

STEP1:   AS OF NOW, CORE, CAVITY , CLIDERS & WWASHERS ARE CREATED. NOW WE HAVE TO CREATE EJECTOR SYSTEM. IT CONSISTS OF EJECTOR PINS & PLATES. STANDARD EJECTOR PIN IS OF ø6mm. NOW MAKE SOME EXTRUDE CUT FOR THE PROVISION OF EJECTOR PIN.       STEP2:     NOW CREATE EJECTOR PINS.…

STEP-1:- UNDERSTANDING THE MODEL & DECIDE THE TOOLING DIRECTION. THEN SELECT DRAFT ANALYSIS OPTION HERE SELECT TOOLING DIRECTION & GIVE DRAFT ANGLE AS 0.5°. CAVITY SIDE SHOWN AS GREEN SURFACE CORE SIDE SHOWN AS RED SURFACE SINCE THE GIVEN MODEL HAVE LESSER DRAFT ANGLE, COMMUNICATE TO PRODUCT DESIGN TEAM.  …

Tree Structure:-       A detailed report should be done explaining the draft analysis and the tooling axis creation.                Look for the tooling direction in all 3 axis and find out the best possible direction.     Tooling direction in x-axis  …

Tree Structure:-   SELECTION OF TOOLING DIRECTION:-                FOR THIS MODEL, IF WE HAVE X-AXIS AS A TOOLING DIRECTION, IT CAN'T BE TOOL ABLE BECAUSE HAVE UNDER CUTS. SO WE NEED LOOK FOR OTHER AXIS.      SAME IN THE CASE OF  Y-AXIS AS A TOOLING DIRECTION…

Tree Structure SELECTION OF TOOLING DIRECTION:-                FOR THIS MODEL, IF WE CHOOSE X- AXIS AS A TOOLING DIRECTION, IT FORMS PARTING LINE ALONG THE SURFACE AND ALSO IT NEEDS SLIDERS. SO WE NEED LOOK FOR OTHER AXIS.          FOR THIS MODEL, IF WE CHOOSE…

STRUCTURE TREE   FRONT VIEW   SIDE VIEW TOP VIEW  

CREATION OF TOOLING AXIS:-                             Since the give model is have 90° angle , we have to communicate to Class - A surface design to consider this and give minimum draft angle possible.      Here , We are choosing…

DRAFT ANALYSIS FOR CLASS - A SURFACE DRAFT ANAYSIS ON SWITCH BEZEL COMPONENT:-                        In this door bezel model, Red coloured is cleared by core side & Green coloured side is cleared by cavity side.   creating the tooling axis                           Firstly in X-axis , draw an bisecting line beween two…

  DESIGN RULES FOR RIB CREATION:- THICKNESS OS THE COMPONENT - 2.5mm 1) Minimum thickness at the tip - 0.75mm , here 0.786mm -  satisfy the rule 2) Draft angle - 0.5°Min - 3°, here 0.5mm -  satisfy the rule (Ideal draft angle -1.5°) 3) Distance beetween the two ribs - 2t (Min.) = 2*2.5 =…

  DRAFT ANAYLSIS OF FINAL COMPONENT:-   For Ribs & Screw bosses Minimum draft angle given is 0.5°. For Dog house draft angle given is 1.5°.   DRAFT ANAYLSIS OF DOG HOUSE:-  Since the dog house placed perpendicular to the normal tooling axis, it can be cleared only with the help of side core.…

CREATION OF TOOLING AXIS:-              TOOLING AXIS IS CREATED NORMAL TO SURFACE.   DRAFT ANALYSIS OF CLASS -A SURFACE:-   DRAFT ANAYSIS OF FINAL COMPONENT:-             GREEN COLOURED SIDE IS CLEARED BY CAVITY SIDE & RED COLOURED SIDE IS CLEARED…

CREATION OF TOOLING AXIS:- IN THIS PROJECT TOOLING AXIS IS CREATED WITH THE HELP OF MASTER SECTION   LIFTER TOOLING AXIS:-     TREE STRUCTURE:-     DRAFT ANALYSIS:-      

QUICK RETURN MECHANISM:-   TREE STRUCTURE:-   CV JOINT:-   TREE STRUCTURE:-

Aim:- To create a Door trim panel from given class A surface and master section along with door panel attachment by following the design guidelines. Introduction:- Door trim panel is an interior component (plastic component) attached to the inner side (sheet metal component) of the door. Plastic has revolutionized…

BENCH MARKING Bench marking is a process of involves in a structured comparison between similar products, services or processes on some dimensions of performance. In other words, bench marking is a analyzing of similar product with some criteria and conclude the final result. CASE STUDY:- Mr. D.S. Pughazhyendhii is…

UNDERBODY COATING:- Underbody coating is usually a dense cladding (often based on rubber) applied uniformly to the undercarriage of the automobile.  Purpose The overlapping, spot-welded metal sheets must be sealed in such a way that no humidity can penetrate between the metal sheets and water in the vehicle interior,…

DESIGINING OF HOOD INNER PANEL, OUTER PANEL AND THE NECESSARY REINFORCEMENT BY FOLLOWING THE MASTER SECTION   OBJECTIVE The main objective of the project is to designing of hood inner panel, outer panel and the necessary reinforcement following the master section and Euro NCAP standard that satisfies the manufacturing…

FENDER DESIGN – WHEEL ARCH   Objective: - To calculate the ga between the wheel arch of the fender to the tire and to conclude that the car will pass the European standard or not. Fender: - A fender is the curved portion of the car's body that sits over and houses the wheels. The purpose of a fender is pretty…

Aim To calculate section modulus of hood and optimize the design to have improved section modulus. Section modulus:- Section modulus is a direct measure of a strength of any cross sectional area of an object about an reference axis. The formula of section modulus is given by, S=I / Ymax Where, I = Moment of inertia (mm^4)…

FENDER MOUNTINGS AIM  The main aim of the project is to develop the fender mounting following the given master section. FENDER A fender is the curved portion of the car's body that sits over and houses the wheels. The purpose of a fender is pretty simple. Its purpose is to keep mud, rocks, and other road debris from being…

ROOF DESIGN Aim:- To design the roof of an car along with its reinforcement following the master section & design procedure. Objective:- To design the roof and its reinforcement Perform draft anaylsis To do curvature study on the roof and perform calculations to determine the position of the Bow-roofs. Curvature study…

Design of Car Backdoor Aim To design a Backdoor of a car from the given styling surface and following the design standards. Introduction Backdoor of a car generally give access to the vechicle's main storage area (or) cargo compartment by opening and closing which is co-ordinated by latch,sticker, gas stay. Position of…

1.What is BIW & define its parts?            BIW stands for Body in White. BIW is an assemblage of all welded sheet metal panels as before going for priming and painting. BIW refer to the welded sheet metal structure to which other component will be married i.e. engine, chassis, exterior and interior trim. Body in white…

1. What is the process of project execution activity? Project execution is the stage of the project where everything has been planned is put into action. The main objectives are: To keep the work on track To organize team members To manage timelines To make sure the work is being done according to the original…