Section Modulus calculation and optimization

AIM 1. Initiate a rough concept of Fixture design with reference to all the inputs provided for the given Car panel. 2. Complete 3D finish work. 3. Complete 2D finish with Output documentation.   INTRODUCTION BIW ( BODY IN WHITE ) Body in White (B.I.W.) refers to the welded sheet metal components which form the vehicles…

AIM Create a BOM and Hardware list (BOP) for the complete Fixture assembly from challenge 8.   What is BOM  A Bill of Materials (BOM) is a list of all the components and parts needed to manufacture a product or assembly. In a drawing sheet, the BOM is typically included as a table or list of items, with information such…

Create 2D Drawing for each Clamp Units with all child parts and also create Child pard drawing for the same for the Fixture assembly created in challenge 8. Swivel clamp unit 1 Swivel clamp unit 2   Create 2D Drawing for each Pin Units drawings with all child parts and also create Child pard drawing for the same for the…

Aim: 1)Draft a Key Sheet for the Complete Fixture assembly created in challenge 8. 2)Draft a Base Unit and the Fix Pin Unit drawings with all child parts for the complete Fixture assembly from challenge 8. Key Sheet For Complete Fixture Assembly:   Base Unit Drawings: 4 way Pin Unit  Drawings: Conclusion A detailed drafing…

What are the Drawing templates? Drawing Templates are the standard drawing files that are used to detail the 3D Models like part modelling, product layout, etc. Drawing templates are basically the drawing standards as per customers specifications. Drawing templates are format that are used for detailing of different parts…

AIM To perform 3D finish and design Rough locators for the Fixture assembly design.   Rough Locators: Rough locators are basically used where manual loading of panels are to implemented on the fixture. These are used to guide the panels in correct position & orientation. These also help for proper Poka -Yoke. Materials…

What do you understand by the 3D finish process? 3D finish process means to finish the design is being completely and make it ready for final simulation & 2D detailing. The following are the basic rules to be followed in 3d finishing:  The nominality of holes is to be checked which ensures the easy assembly of all the…

AIM Design a Base Unit for the units designed for the above challenges with all weldments for the given Car Panel.VDesign a Base Unit for the units designed for the above challenges with all weldments for the given Car Panel. INTRODUCTION BASE  UNIT A base unit is the unit designed to mount all other units like clamp unit,…

What is the Base Unit? What are the typical parts of the Base Unit? A base unit is the unit designed to mount all other units like clamp unit, pin unit, rest unit etc. of the tool also other parts necessary for a tool like pneumatic valave box,trunking cable path will also be mounted on to a base unit.    Typical parts…

AIM Design 3 Different types of Swivel Clamp Unit with Different Riser, Blade, and Clamp Arm for the given Car Panel.  Design a Pin-Clamp Unit for the given Car Panel.   INTRODUCTION In Fixture design, we have to arrest all degree of freedom by locating the panel at required position, after that we will design the fixture…

Objective Design 3 Different types of Power Clamp Unit with Different Riser, Blade and Clamp Arm for the given Car Panel. Design 2 Different types of Rest Unit for the given Car Panel.   Introduction Clamp unit A clamp unit is a unit designed to clamp or hold the car panel with NC blocks / mylars / rest by using a pnewmatic…

Objective  Design 2 Different types of Fixed Pin Unit & 2 Different types of Retractable Pin with Different Pins, Riser, Blade, and Block. Pin unit Pin unit is used to lock the rotational position of panel. Round Pin is used to control panel in two directions while Diamond Pin is used to control panel in one direction.…

1. What is Design Methodology? Design Methodology is nothing but the  steps followed during the concept designing stage of fixture  design   2. What are the inputs required from the customer to start designing a Fixture ? 1. Functional requirement Welding fixture Hemming fixture Checking fixture Storage…

1. What is the process of project execution activity? It is a general activity which is involved in BIW fixture and tooling. It is a starting phase of every project. It starts with basic requirements,We received from the customer. There are various steps involved in project activities. 1. RFQ Request for quote (RFQ) is a…

1.What is BIW & define its parts? Body in White (BIW) refers to the welded sheet metal components which form the vehicles structure to which the other components (like engine, chasis, exterior & interior trims) will be married or assembled BIW Parts: there are 5 majors parts in BIW as mentioned below 1. Body sides…

Assemble and apply GD&T to the butterfly valve assembly drawing Step-1: Assemble the Disc plate to shaft Step-2: Assemble the Shaft to body Step-3: Assemble the Body to  retainer Step-4: Assemble the Shaft to  handle Step-5: Assemble the nut  to handle   Drafting process All dimensions are mentioned…

OBJECTIVE Use the provided styling surface to come up with a back door design, use appropriate design methodologies, and provide the necessary reinforcements and embosses Given Class A surface   BACK DOOR (TRUNK DOOR) Back door or tail gate  simply refers to the back of the car that can open and close.it covering…

OBJECTIVE The main objective of this project is to develop the car roof design and its reinforcements from the given styling surface & Master  section. And to prepare a detailed report about the engineering standards for roof design, its design procedure, Draft analysis and manufacturing techniques.   CAR…

AIM To create Fender design by using given Class A surface. For the Sill, Bumper, Baffle(Splash), and A-Pillar mount create your own design according to the Engineering standard that you learned. Prepare a report with all the relevant images included for the mounting points created. FENDER Fender is  a …

FENDER STANDARD & REGULATION Why are these standards between the fender and the wheel? The  standards state that the  wheel of  the vehicle should be housed inside the boundaries of the fender so  that the purpose of having a fender is met, which is to pervent the wheel from spraying debris and…

AIM Use the Section from your Hood design and calculate the Section Modulus using the formula  S = I/y  Where,  S = Section Modulus I = Moment of Inertia y = distance between the neutral axis and the extreme end of the object    SECTION MODULUS Section modulus is a  geometric property for…

AIM Design Hood Outer Panel, Inner Panel and the necessary reinforcements by following the Master Section mentioned with the Design parameters explained in the videos.  Submit an ASSEMBLY of Hood Inner Panel, Outer Panel, Latch, Hinge and the Reinforcements.A detailed report about the Hood Design which includes a detailed…

1. Write a one-pager about Under-Body Coating and its purpose, its types in detail, and its pros and cons. UNDERBODY COATING 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…

Benchmark Benchmarking is a tool to improve product design and user experience based on your competitors and similar products. Don't forget to prioritize your product strategies through the insights generated from the analyses. Benchmarking in business means measuring your company’s quality, performance and…

PROJECT 2 Route the Wiring harness on the given car body and prepare a flattened view drawing in CATIA V5. Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required. AIM Route the Wiring harness on the given Trunk door and…

PROJECT 1 AIM  Route the Wiring harness on Given Engine and Prepare flatten view drawing in CATIA V5. Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required. ENGINE WIRING HARNESS ROUTING  The above figure shows…

Q1. Flatten the harness assembly completed in “ week 4 challenge”. Place the flattened view on drawing sheet. Ensure bundles with protective coverings has different visuals on drawing view. Aim To Route the following harness layout in the Electrical workbench. Add protective covering on all branches Flatten the harness…

Q1. Route the following harness layout in Electrical workbench. Make assumption for harness bundle diameters. Use the connectors provided. After completion of routing, Electical definition of given connectors Define all the electrical connectors geometrically and electrically so that they can be used in the wiring harness.…

Q1. Route the following harness layout in Electrical workbench. Make assumption for harness bundle diameters. Use Following connectors as shown in layout diagram. Add protective covering on all branches connected to DT06-2S & DT06-4S connectors. Keep end extremity at 30mm (from connectors end)   Aim To Route the…

Q1. Download following cad data & define it as Electrical support using Electrical Part design Workbench. Define all the necessary properties. P clamp Step 1 Define geometrical parameter point & plane at entry Step 2 Define geometrical parameter point & plane at entry Step 3 Define geometrical parameter plane…

Aim Download following connectors & Connector clip cad data from given link & define it as Electrical Connector using Electrical Part design Workbench. Define all the necessary properties to Connectors & Clip. Deutsch DT06 – 08SA ( https://www.te.com/usa-en/product-DT06-08SA.html) Tyco 174357-2 (https://www.te.com/usa-en/product-2-174357-2.html?source=header-match)…

Door Trim panelOBJECTIVETo design the following requirement for the given class A surface and master section sketch.Tooling Axis creation & Draft analysisClass B surface & class C surfaceClose Body and thicken partCreation of additional engineering features.Assemble the push pinComponents involved in the Door panel…

Quick return mechanism Body 1   Body 2 Body 3 Body 4 Body 5 Full assembly Detailed tree structure Drawing work bench CV Joint Body 1 Body 2 Body 3 Assembly Detailed tree structure Drawing work bench  

 A Pillar Objective  To make a full solid model from the provided master section and class A surface   TOOLING AXIS CREATION: First create the class A surface and manually analysis and fix the direction of tooling. In this part two hole on the surface. So, we can directly take its perpendicular as the tooling…

Door Applique Heat Stakes design   Counter Part Thickness - Will be given as input Component Wall Thickness - Will be given as input Length of the Rib - 20 mm Height of the Ribs - 3 mm to 6 mm Inner Diameter of Heat Stake (d) - 5 mm Outer Diameter of Heat Stake (d) - 7 mm Minimum clearance between heat stake and counterpart…

Door trim Tooling Axis creation: It is defined as the direction in which the mould/core and cavity open. Selection of the direction of the tooling axis depends on the ease at which components can be easily ejected. By analysing the component the most easily ejectable direction is somewhere close to the Z direction,(might…

Door handle   CREATING TOOLING AXIS -                   The Tooling Direction is basically the direction that the mold pulls a part. The mold is built in two separate pieces, basically. You have a Cavity side and you have the Core side. The Core pulls apart from the…

Creating the Tooling Axis The tooling direction is used to find the direction in which the part is removed from the core and cavity. The draft angle should be positive to the tooling axis to manufacture the component easily. The step by step procedure of creating the tooling axis is given below. Step: 1 Creating the point…

 Door Trim Lower Tooling Axis : here first we required tooling axis for draft analysis. tooling axis is works as provided to direction for injection moulding as well as direction of draft angle where is check it right or wrong so 1st we extract the surface of class A and than create point on it use this point we create…

 Bumper  Creation of Tolling axis:  To create the tooling axis first we have to check the best suitable direction for tooling by using the compass. the x direction is suitable for creating the tolling axis because in the x direction most of the surfaces are clearing while performing draft analysis. Generally…

Coin Holder  Creating the Tooling Axis The tooling direction is used to find the direction in which the part is removed from the core and cavity. The draft angle should be positive to the tooling axis to manufacture the component easily. The step by step procedure of creating the tooling axis is given below. Step:…

Draft Analysis Draft Analysis for Class A surface:   Step: 1 Initially we perform the draft analysis to the class a surface to ensure that we have good quality of surface to make Class B and C surface to achieve the same kind of quality surface. First we have to set the compass on the main tooling axis to get the…

Screenshots of the Draft analysis report for both the given Class-A surface and the final plastic component Class A surface complete Draft analysis  color scale variant Solid body solid model with the proper color code of the draft angle in various orientations Isometric Front  Top View   Work on to write…