Section Modulus calculation and optimization

CPU FAN BEZEL MOLD DESIGN   Aim: To create a complete mold block for CPU fan bezel model. To design slider, ejector pins, sprue, runner, gate and cooling channels for the mold blocks.   Procedure: First import the model in the part file and save the file. Check the given part properly. Perform a draft analysis…

Aim: To create a proper ejection system with ejector pins and plates, runner and gate system, air vents and cooling channels for the mold.   Procedure: In the previous challenges we have created the mold blocks, inserts, sliders for the plastic knob component.   in order to create the ejector pins, create a sketch…

Aim: To create 2 sliders for the 2 undercuts present in the CPU fan case model. To create inserts in the model wherever required.   Procedure: In previous challenges we have created the mold blocks for the door bezel as shown below:     Activate the core block first, then select a reference surface to choose…

Aim: To create mold blocks for the table fan stand. To create the ejectore pins To create sliders and undercuts for the door bezel mold block.   Procedure:   Analyse the component and decide the tooling direction for the mold design. Then perform draft analysis to check whether the drafts provided component surface…

Aim: To create 2 sliders and 2 undercuts for the door bezel mold block.   Procedure: In previous challenges we have created the mold blocks for the door bezel as shown below:     Plan to create the sliders: When we use only core and cavity block and the material solidifies, it will be impossible to seperate…

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

AIM: To create Bill of Material (BOM) and Hardware list (BOP) for the complete fixture assembly.   BILL OF MATERIALS (BOP) A bill of materials (BOM) is a comprehensive inventory of the raw materials, assemblies, subassemblies, parts and components, as well as the quantities of each needed to manufacture a product.…

Pin Unit 1:   Pin Unit 2:   Clamp Unit 1:       Clamp Unit 2:     Clamp Unit 3:       Clamp Unit 4:       Clamp Unit 5:  

OBJECTIVE : To draft a Key Sheet for the Complete Fixture assembly created earlier. To draft a Base Unit and the Fix Pin Unit drawings with all child parts for the Complete Fixture assembly created earlier.   Assembly:   Base Unit:   Fix Pin Unit:

1. What are the Drawing templates? Drawing templates are basically the drawing standards as per the customer specifications. Drawing templates are the formats used fro detailling of diffenrect parts or units of a fixture.  The "n" numbers of details, that are available on the templates and are useful for various…

Aim: Perform 3D finish for all units of car panel fixture ssembly design. Create Rough locators for fixture assembly.   Introduction: 3D finish is process where the design is being completely finish and to be ready for final simulation and 2D detailing. Points to be considered while finishing the…

1. What do you understand by the 3D finish process? 3D finish is process where the design is being completely finish and to be ready for final simulation and 2D detailing.   2. What are the points need to be taken care of while finishing the design? Hole concentricity and hole sizes: All parts Hole…

Base Unit Design   AIM: To design a Base Unit for the aready units designed with all weldments for the given Car Panel. To design the complete Fixture assembly.   Introduction: Base unit is the unit designed to mount all theother units such as fix pin unit, clamp unit, rest unit…

1. What is the Base Unit? What are the typical parts of the Base Unit? Base unit is a unit which is used to mount all the units such as clamp unit, pin unit, rest unit etc., of a tool and also other necessary table parts like pneumatic valve box, trunkin cable path.   Typical parts of base units are given as in the…

Aim/ Objective: The main objective of this project is to - To Design 3 Different types of Swivel Clamp Unit with Different Riser, Blade, and Clamp Arm for the given Car Panel. To Design a Pin-Clamp Unit for the given Car Panel. To maintain the stroke as 100mm.   INTRODUCTION:  A Clamp unit is used to hold the…

CLAMP UNIT AND REST UNIT DESIGN   AIM: To design 3 Different types of Power Clamp Unit with Different Riser, Blade, and Clamp Arm and design 2 Different types of Rest Unit for the given Car Panel.   INTRODUCTION   The principle of location is being discussed here with the help of a most popular example which…

DESIGN OF FIX PIN AND RETRACTABLE PIN UNIT   AIM: To design a different types of fixed pin unit and retractable pin unit with different pin, riser, blade, cylinder and block   INTRODUCTION: FIXED PIN Fixed pin unit is a unit designed to locate the car panel using pins. Pin, pin retainer, shims, blocks, blade,…

1. What is Design Methodology ? Design Methodology is nothing but the steps followed during the concept designing stages of fixture design. The key to design methodology is finding the best solution for each design situation, whether it be in industrial design, architecture or technology. Design methodology also…

Q1. What is the process of project execution activity?  Project activities are the tasks from the start to end of the project. There are various steps involved in the projects. The various steps are described below. RFQ received: This id the first step in any project. RFQ stands for Request for Quotation.…

BODY IN WHITE (BIW)   Body in White (B.I.W.) refers to the welded sheet metal components which form the vehicles structure to which the other components will be married, i.e., engine, chassis, exterior and interior trim.  BIW refers to the stage in automotive design or automobile manufacturing in which the car…

DESIGN OF CAR BACKDOOR WITH NECESSARY REINFORCEMENTS   Aim: To design the complete back door assembly along with reinforcements of the car from the provided class A surface using proper design methologies.   Introduction: The trunk or boot of a car is the vehicle's main storage or…

AUTOMOTIVE CAR ROOF DESIGN   Aim: To create side flanges and reinforcements (roof rails)  for the given car roof skin and also carry out curvature study along with draft analysis.   Introduction: An automobile roof or car top is the portion of an automobile that sits above the passenger…

Automotive Fender Design Aim:To design automotive fender from the given fender skin model and also to create different mountings on it for attachment. Introduction:Fender is a metal or plastic enclosure over the wheels of an automobile or other vehicle to protect against splashing mud,…

Fender Design - Wheel Arch Challenge   Aim: To calculate the wheel arch area of the given fender model and validate whether the fender design pases the European Standards or not.   Introduction: Fender is a metal or plastic enclosure over the wheels of an automobile or other vehicle to…

Section Modulus calculation and optimization   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 design include area for tension and shear, radius of gyration for compression, and moment…

CAR HOOD DESIGN AND ASSEMBLY.   Aim: Design Hood Outer Panel, Inner Panel and the necessary reinforcements by following the Master Section mentioned with the Design parameters.   Introduction:   Hood: A car hood also referred to as a bonnet in some other countries is the hinged cover that rests over the…

Underbody Coating   Underbody refers to the belly of your car, the underside that sits closest to the road. In order to protect the vehicles unerbody from corrosion (rust) as well as small tear and wear from foriegn objects. Underbody coating is usually a dense cladding (often based on rubber) applied uniformly…

Benchmarking   Benchmarking is defined as the process of measuring products, services, and processes against those of organizations known to be leaders in one or more aspects of their operations.  Benchmarking involves a structured comparison between similar products, services or processes on some dimensions…

Development of Door trim panel   Aim : To Create the Door Trim panel through the given Class-A surfaces by creating a required tooling axis and various attachments.   In automotive design a Class A surface in any of a set of free form surfaces of high efficiency and quality. Although strictly its nothing…

Quick Return Mechanism   Slotted Lever.   Base   Rectangular slider   Connecting Rod   Circular slider Assembly     CV Joint Part 1   Part 2     Part 3   Assembly

Aim: To Create the A pillar through the given Class-A surface and master section by creating a required tooling axis.   Objective: To create a class A and Class B surface using given surface and mastersection. To create the dog house and attach to the A pillar. Perform Draft analysis on the compenent. Create…

Aim: To Create the Door Trim through the given Class-A surface by creating a required tooling axis.     Procedure for Designing Door Trim:   To start with is to download and open the below class A file of the door trim. Now check the continuity of the surfaces using boundary option. There should…

Design of Dog House for the Door Trim   AIM: To Create the solid component from the given Class-A surface of Door Trim. To Create the tooling axis for the given Class-A Surface meeting the requirements of the draft angle. To perform the Draft analysis on the model. To create a dog house attachement to the door trim component.…

Draft analysis and Feature Attachment creation of Door Hndle   AIM: To Create the solid component from the given Class-A surface of Door Handle. To Create the tooling axis for the given Class-A Surface meeting the requirements of the draft angle. To perform the Draft analysis on the model. To create a rib and screw…

Core and Cavity Design of Switch Bezel   Aim : To Create core and cavity block for the Switch Bezel Component.   To start with is to download and open the below class A file of the switch bezel. Now check the continuity of the surfaces using bounddary option. There should not be not gao between the surfaces.     1) Tooling…

Design and Draft analysis of a Car Bumper component.   Aim: To Create the Bumper component through the given Class-A surface by creating a required tooling axis.     Procedure for Designing Bezel   To start with is to download and open the below class A file of the bumper. Now check the continuity…

Aim: To Create the Switch Bezel Plastic component through the given Class-A surface by creating a required tooling axis.   Introduction Automotive bezel is a trim or bodywork that surrounds a light, holds the face of an instrument in position, or decoratively conceals gaps between bodywork and components…

Design and Draft analysis of a Switch Bezel plastic component.   Aim: To Create the Switch Bezel Plastic component through the given Class-A surface by creating a required tooling axis.   Introduction Automotive bezel is a trim or bodywork that surrounds a light, holds the face of an instrument in position,…

Aim: To Create the Base Bracket Plastic component through the given Class-A surface. Objectives:  Ensure Proper Tree Structure Geometrical sets should have a proper name based on the sketches present inside of it All the sketches should be created under the Geometrical set  Use the Close Surface feature…

 Aim: Route the wiring harness for the given Car Tailgate assembly and create the flattening view of the harness using CATIA V5.   Assumptions: Appropriate clerance should be provided between the harness and the surrounding component. Minimum distance between the breakouts should be 50mm. Provide additional slack…

Aim: Route the Wiring harness on V16 Engine and Prepare flatten view drawing in CATIA V5. Objective: The main purpose of this report is to understand the basic fundamentals of the Electrical Wiring Harness and also define the electrical connncetion to the connector and connnecter clip using Electrical Part Design Workbench…

Aim: To create flatten view of the previously prepared Electrical harness assembly in Catia V5.   Objective: Flatten the harness assembly prepared in week 4 challenge. Place the flattened view on drawing sheet. To add the protective covering and enusre that it is of different colour in drawing.   Procedure: Open…

                           Modelling, Assembly and Photo-realistic Rendering of American Chopper Bike using Solid works.   Objective: The main purpose / objective of this project is to understand functions of solidworks and solidworks visualize…

Aim: To Create as routing harness assembly between th connnectors using Electrical harness workbench in Catia V5. Objectives:  To create the route the harness layout using Electrical workbench in Catia V5 with given set of connnectors. To add the protective covering over the branches. To add annotations to the…

Aim: To Create as routing herness assembly between th connnectors using Electrical harness workbench in Catia V5. Objectives:  To create the route the harness layout using Electrical workbench in Catia V5 with given set of connnectors. To add the protective covering over the branches.   List of Connectors: DT06-4S…

Objective: The main purpose of this report is to understand the basic fundamentals of the Electrical Wiring Harness and also  define the electrical connnection (support) to the Clamp and backshell using Electrical Part Design Workbench in Catia V5.   1) P Clamp: A P clamp or also known as pipe clamp is a…

Objective: The main purpose of this report is to understand the basic fundamentals of the Electrical Wiring Harness and also  define the electrical connncetion to the connector and connnecter clip using Electrical Part Design Workbench in Catia V5 Introduction:A Wire harness, also known as cable harness, wiring…

Modelling, Assembly and Rendering of Sunseeker Predator Yacht using Solid works.   Objective: To create a 3D model of invidual parts of Yacht. To assemble all the parts of Yacht together. To perform rendering of the Sunseeker Yatch using Solidworks Visualize.   1. Introduction: Sunseeker Predator Yacht was manufactured…