Fender Design Challenge

Butterfly Valve Assembly Modelling In this challenge, we are going to assemble all the parts that we have created in earlier challenges for the Butterfly Valve and also plot a 2D drawing for the same by applying GD&T principles. The parts of the Butterfly Valve include, Body Shaft/Stem Disc Retainer Lever Nut M12 Screw…

                                                                      WIRING HARNESS FLATTENING In this challenge, we are going to perform the flattening…

                                                             Wiring harness design in CATIA V5 - 3D modelling  In this challenge, we need to route the given harness…

                                                                      Wiring Harness Routing In this challenge, we are going to route the wiring…

                                                       Wiring Harness Routing & Packaging Rules  In this challenge, we are first going to define a mechanical cad component…

                                                             WIRING HARNESS DESIGN   What is Wiring Harness? A wiring harness is one of the most essential…

Wiring Harness Routing of Back Door Panel of a Car In this challenge, we will perform the Wiring Harness Routing of a Back Door Panel and at the end will prepare a flattened view drawing for the same. All packaging rules & the best industry practices will be followed during this process. The steps that need to…

Wiring Harness Routing of 16-Valve Engine In this challenge, we will perform the Wiring Harness Routing of a 16 Valve Engine and at the end will prepare a flattened view drawing for the same. All packaging rules & the best industry practices will be followed during this process.  The steps that need to be…

Aim: To Design & Develop the Back Door Panel of a car using styling surface as input and also creating the necessary reinforcements and embosses. Introduction: Back Door: The back door is placed at the rear end of a car at which the loads can be kept. It is also called a trunk or tailgate. It consists of an outer panel,…

Aim: To design & develop the Roof of a car with its components by following the master section and design parameters. Objective: To develop the essential flanges and reinforcements using roof styling as input. To do a curvature study on the roof and perform calculations to determine the position of the Bow-roof. To…

AIM: To generate midsurface and perform geometry clean up on the given component and also generating the mesh with low tria concentration under the given quality parameters. SOFTWARE: Hyperworks 2020. PROCEDURE: First import the CAD model in HYPERWORKS. After importing the model, generate the Midsurface manually by using…

AIM: To generate midsurface and perform geometry clean up on the given component and also generating the mesh with low tria concentration under the given quality parameters.   SOFTWARE: Hyperworks 2020.   PROCEDURE: First import the CAD model in HYPERWORKS. After importing the model, perform geometry cleanup…

Aim: To design a front fender from the given skin data and the master section provided with Drip mounting, A-pillar, Sill, Bumper, and Cowl mountings. Theory: What is Fender? A fender is a part of the automobile that is placed just above the tyres/wheels (both at the front & back). The purpose of the fender in an automobile…

Aim: To Design & Assemble Hood outer panel, inner panel and the necessary reinforcements by following the Design parameters & Master section which is given to us as an input. Abstract: The project report deals with the explanation of steps and procedure followed while developing the HOOD Assembly of a car using…

Aim: To calculate the section modulus of the hood and to modify the design for improving its strength. Theory: Section modulus: Section modulus is a geometric property for a given cross-section used in the design of beams or flexural members. Other geometric properties used in the design include an area for tension and…

What is the underbody coating?    A car underbody is most prone to corrosion. Underbody coating provides long term protection from corrosion to a 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.…

What is 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, aka “best in class.” The point of benchmarking is to identify internal opportunities for improvement.…

Aim: To set up the case for ROOF CRUSH - BIW OF NEON car and successfully simulating while also plotting the graphs for the results obtained. SOFTWARE: HyperWorks 2020 USER PROFILE: RADIOSS OBJECTIVE: The objective of the challenge is to follow the below-given steps: Import Car Impactor Transforms This will require…

Aim: To create a CAD model (Door Trim Panel) with attachment features considering the given inputs, design rules and following the OEM standards. Abstract: The project report deals with the explanation of steps and procedure followed while developing the Door Trim Panel of a car using CATIA V5. Using the CLASS-A surface…

Aim: To create a B pillar of a car using the master section and styling surface as an input and performing Draft Analysis on the final model (3D CAD model). Objective: To ensure proper tree structure is followed. Creating a tooling axis and following design rules. Creating CLASS B and C surface using CLASS A surface as…

Aim: To design the Door Applique with engineering features such as Heat stakes and Locators, given styling surface / CLASS A surface as input and also to perform Draft Analysis on the final 3D CAD model. Objective: To ensure proper tree structure is followed. Geometrical sets should have a proper name based on the sketches…

Aim : Create the dog house and screw bose on the Centre console coin holder considering the design rules. Objective :  General Guidelines for Bosses:   Draft  - 0.5 degrees on walls of boss   Thickness -  Typically 40%* of the nominal wall at the base.   Height to Diameter Ratio…

Aim : To create the rib for the Centre console coin holder considering the design rules. Introduction: Plastic parts design is a very complex process and it requires the involvement of many factors like functional requirements, process constraints, material selection and assembly or structural issues. Wall thickness, Draft,…

AIM:To create a switch bezel from the given A-class surface by considering a thickness of 2.5 mm and also creating Core and Cavity blocks for it. PROCEDURE: A class surface : The input of the product designer is in the form of the A-class surface. The job of the product designer is to create the B and C surfaces keeping…

AIM: Creating  the coin holder plastic component through the A-class surface and add thickness to it    Objective : Creating the B and C surface  Creating the tooling axis  Performing the draft analysis on both A surface and final plastic components. Take the Thickness of the component to be 2.5…

Aim: To create the Switch Bezel Plastic component through the given Class-A surface and also performing draft analysis on it at the end. Objective: To ensure proper tree structure is followed. Geometrical sets should have a proper name based on the sketches present inside of them. All the sketches should be created under…

Aim: To Create the tooling axis for the given Fan cover model meeting the requirements of the draft angle and performing the draft analysis on the model. Objective: To ensure proper tree structure is followed. Geometrical sets should have a proper name based on the sketches present inside of them. All the sketches should…

Sketch solving status’s geometry tab: SKETCH 1: SKETCH 2: SKETCH 3: SKETCH 4: SKETCH 5: SKETCH 6: SKETCH 7: TREE STRUCTURE: 3D CAD MODEL:

Aim: To create the Base Bracket plastic component through the given Class-A surface and also performing draft analysis on it at the end. Objective: To ensure proper tree structure is followed. Geometrical sets should have a proper name based on the sketches present inside of it. All the sketches should be created under…

AIM: Creation of the door arm rest and add thickness to it    Objective : Creating the B and C surface  Creating the tooling axis  Performing the draft analysis on both A surface and final Door armrest and draft analysis must show the positive value and color.   Procedure :   Creating the…

Aim: To set up the case for SIDE CRASH - BIW OF NEON car and successfully running the simulation while also observing the errors and energy changes. SOFTWARE: HYPERWORKS 2020 USER PROFILE: RADIOSS OBJECTIVE: The objective of the challenge is to follow the below-given steps: Check the unit system and either follow [Mg mm…

Aim: To set up the case for FRONTAL CRASH - BIW OF NEON car and successfully running the simulation while also observing the errors and energy changes. SOFTWARE: HYPERWORKS 2020 USER PROFILE: RADIOSS OBJECTIVE: The objective of the challenge is to follow the below-given steps: Check the unit system and either follow[Mg…

AIM: To set up and run the simulation for all the 7 cases in HYPERMESH and compare them to give a proper conclusion. SOFTWARE: HYPERWORKS 2020 USER PROFILE: RADIOSS PROCEDURE: CASE 1: First import the starter file (FAILURE_JOHNSON.0000.rad) in HYPERMESH by going to menu bar > file > import > solver deck. Browse…

BUMPER ASSEMBLY MODEL:   AIM: To create the mesh for bumper assembly with a target element size of 6mm. SOFTWARE: HyperWorks 2020 USER PROFILE: RADIOSS PROCEDURE: First import the model in Hypermesh (in .HM format). After importing the model perform geometry cleanup on the given surface. The surfaces are not connected…

AIM: To compare the simulation results of CASE 1 and CASE 2 i.e, without changing element properties (CASE 1) with improved shell element properties (CASE 2). SOFTWARE: HyperWorks 2020 USER PROFILE: RADIOSS PROCEDURE: CASE 1: First import the starter file to HyperWorks. To import the file Go to "menu bar > File >…

Answers for the Questions 1-6 can be found in the below image.                              Edited engine file can be found below:     7. 3d meshing tetra mesh and hex mesh     MODEL 1: Aim: To create 1D elements and…

Aim: To generate midsurface and perform geometry clean up on the given components and also generating the mesh under the given quality parameters. SOFTWARE: Hyperworks 2020 USER PROFILE: RADIOSS PROCEDURE: MODEL 1: First, import the given HM model in HyperMesh. After importing the model perform geometry cleanup on the…

Aim: To create connectors and attach the various parts of the given model. Software: Hyperworks 2020 Procedure: First import the CAD geometry in the Hyperworks. After importing the model, mesh all the surfaces individually with a target element size of 5mm. Connector 1: Now first attach Right_Rail_2 & Front_truss_1…

MODEL 1: HOUSING   Aim:  To create Tetramesh (3D meshing) on the given component / model.   Software: HyperWorks 2020   Procedure: Firstly import the CAD geometry in the Hyperworks by selecting file type as ‘STEP. After importing the model delete the solids.         Now first…

Aim : 2D Meshing the hood component in HYPERWORKS. Software: Hyperworks. Procedure : Firstly import the CAD model to the hypermesh.                                                  After importing…

Aim: To create 1D elements on a Parallel Bracket (given component/model) with a given cross-section and DOF. Procedure: Initially import the model in Hypermesh by selecting file type as "IGES". Once the model is imported, create mid-surfaces of the component as "Bracket B1 and Bracket B2".        …