Underbody Coating

Rayleigh Taylor Instability Rayleigh Taylor Instability is an instability of the interface between the two fluids of different densities which occurs when the lighter fluid is pushing the heavier fluid. It is clear from Newton's law of viscosity, fluid cannot resist the slightest shear force and density is one of the main…

Conjugate heat transfer (CHT) The Conjugate Heat Transfer (CHT) analysis type allows for the simulation of heat transfer between solid and fluid domains by exchanging thermal energy at the interfaces between them. Typical applications of this analysis type exist as but are not limited to,…

1. Ahmed body and its importance The Ahmed body is a simplified car body used in the automotive field to study the impact of the flow pattern on drag. The external aerodynamics of the car defines many significant traits of an automobile like stability, comfort, and fuel consumption at high speeds. The flow around the vehicle…

Aim: To Simulate the flow over a cylinder and explain the phenomenon of Karman vortex street. Objective: Simulate the flow with the steady and unsteady case and calculate the Strouhal Number for Re= 100 Calculate the coefficient of drag and lift over a cylinder by setting the Reynolds number to 10,100,1000,10000 &…

Aim: Set up steady-state simulations to compare the mixing effectiveness when the hot inlet temperature is 360C & the Cold inlet is at 190C Understand the difference between the k-epsilon and k-omega SST model for the first case  Simulate each case for the given velocity and momentum ratio Compare results from…

CFD Meshing for Tesla Cyber Truck: Could not mesh the wind tunnel as ANSA kept crashing while meshing.  The truck has been meshed completely.       

Topo cleanup: Surface wrap: >>Click on Run  

Topo cleanup: Initially, split the car in half and remove and patch up the surfaces.    PID: Create new PSHELL and apply them.    Meshing: Before meshing, check for certain quality criteria and verify them with each PID region.  Surface mesh: Symmetry: Perform symmetry using transform and remove…

CFD meshing on Turbocharger: Topo cleanup: Initially, the patches and irregular surfaces are cleared. Open surfaces are closed.  PID properties: Rename the PID regions according to the parts and assign them.   Surface mesh: Change the mesh parameters for each part as given in the question and apply the mesh.  Compressor…

Surface meshing on a Pressure valve: Topo cleanup: Minor corrections in faces (indicated in orange) : PID properties: Create a new PSHELL and rename it according to the part. Then, select the respective faces and apply. Meshing: Case 1: 1 mm Case 2: 3 mm Case 3: 5 mm Conclusion: Comparing all three cases, case 1 mesh length…

Backdoor Design: Inner panel: Outer panel: Hinge reinforcement: Gas stay reinforcement: Wiper motor reinforcement: Striker reinforcement: Final Assembly:  

Roof Design: The roof has been designed using the master section provided. This design incorporates 2 bow roofs with a center reinforcement roof. The front roof panel and the rear roof panel are also designed following the master section.  1. Roof outer panel 2. Front roof panel 3. Rear roof panel 4. Bow roof 1 5.…

Fender design: Given Class A surface 1. A pillar mount 2. Drip region Added two darts for rigidity 3. Sill mount 4. Bumper mount 5. Baffles mount After creating the mounts, the fender was thickened to 0.75 mm.  

Fender: Fender is the American English term for the part of an automobile, motorcycle, or other vehicle body that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other road spray from being thrown into…

Section Modulus Section Modulus is a geometric property used to calculate the bending stresses in a structural member. Mathematically, It is defined as the ratio of the moment of inertia of a section about its centroidal axis and to the distance of the extreme layer from the neutral axis. It is denoted by Z. Z = I/ymax…

Hood Design: Outer panel: Inner panel: Hinge assembly: Striker assembly: Hood Assembly: Latch Trajectory: Hemming: Relief rear section: Front relief:

Underbody Coating: In Indian road conditions, a car's underbody is most prone to corrosion. Underbody coating provides long-term protection from corrosion to the car’s underbody. It is usually a dense cladding (often based on rubber) applied uniformly to the undercarriage of the automobile. It is normally sprayed…

Connectors used Support clips Harness Assembly Protection covering Harness drawing

Harness Assembly: . Harness Flattening:

Harness flattening parameters were initially set and the assembly part was extracted using the extract command.   Drawing  

Harness A Harness B Intersection between Harness A and B Annotations CAT.part generation Saved with .igs format

Final Assembly The end extremity is given as 30mm.  Distance measurement

1. The required points and planes are created and the electrical support is defined with entry and exit points and base plane.  2. The required points and axis system were created. Then, in the electrical part design, the part is defined as backshell and backshell connection point and the bundle connection point is defined. …

1. Deutsch DT06 – 08SA The required points are created and bundle connection point and connector connection points are defined. The axis system is also created at the mating side. The part is added to the connectors family catalog.  2. and 3. Assembly The same procedure is followed for the two parts and…

Isometric view Multiple views Part drawing

Development of a Door Trim panel The given cad was split into five different parts under the Product category. Each part was worked on separately, creating the class b and c surfaces and the closed body. Later, the attachment features were added to the parts.  1. Armrest Class A of the armrest had discontinuities…

FINAL PART: DRAFT ANALYSIS ON DOG HOUSE: MAIN TOOLING AXIS SIDE TOOLING AXIS

FINAL PART DRAFT ANALYSIS (LOCATOR AND HEAT STAKE)  

  DOG HOUSE DRAFT ANALYSIS Outside draft check Inside draft check Comment: Draft missing on the inside surface   DRAFT ANALYSIS AFTER CORRECTION    

FINAL PART: RIB DESIGN ANALYSIS: SCREW BOSS DESIGN ANALYSIS: DRAFT ANALYSIS:

 DRAFT ANALYSIS: CLASS A FINAL PLASTIC COMPONENT TOOLING AXIS CREATION 1. The class A surface was checked in all the views and the yz plane was convenient. So, a face on the yz plane was extracted. 2. A point was created on the surface and a line was created on the point in the X direction. That is our tooling axis. …

DRAFT ANALYSIS Color code: Red - < 0deg, blue - 0-2deg, green - >2.9deg  CLASS A  FINAL PLASTIC COMPONENT TOOLING AXIS CREATION Procedure: 1. Extract the base face where the tooling axis is needed 2. Create a point on the surface and insert an axis system using that point   3. Create a positioned sketch…

DRAFT ANALYSIS Class A surface Final Plastic part TOOLING AXIS CREATION Procedure: 1. First create a dummy tooling axis using point and line definition     2. Next, create a plane using the reference plane and point.  3. Now, perform the intersection definition for the plane and the class A surface 4. Once…

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Thermal modeling of battery pack: A 10-cell series lithium-ion battery model is made in MATLAB and simulated at different temperatures of 298K, 310K, and 323K. The area of contact is also varied for each cell. The pack is modeled in such a way that each cell's temperature could be measured.  Model: 10s battery subsystem:…

Battery pack capacity: 18 kWh Cell: ANR26650M1-B  Lithium iron phosphate (LiFePO4) battery technology delivers high power and energy density combined with excellent safety performance and extensive life cycling in a lighter-weight, more compact package. The cells are inherently safe over a wide range of temperatures…

1. Simulate the 3 test cases from the harness dashboard. The harness dashboard is shown below,   We can select the test cases from the Test Sequence Variant block. The Test Sequence Variant block parameters is shown below, Results: Test case 1 Observation - There were multiple fluctuations in the pack…

Battery Type Material Electrolyte Reactions (Discharge) Cathode Anode Salt Solvent Anode Cathode LCO LiCoO2 Graphite LiPF6 Ethylene Carbonate C6Li --> 6C + Li+ + e- Li1-xCoO2 + xLi+ + xe- --> LiCoO2 LMO LiMn2O4 Graphite LiPF6 Ethylene Carbonate C6Li --> 6C + Li+ + e- Li1-xMn2O4 + xLi+ + xe- -->…

P1 Hybrid Architecture: Positioned between the engine and transmission, the P1 hybrid architecture and Integrated Starter Generator enable high-efficiency power generation while featuring regenerative braking and acceleration assist. This hybrid technology enables high-efficiency power generation and motoring capability…

Objective: Data visualizer (100 points) Your script should take column numbers as the input and plot the respective columns as separate images Each file should be saved by the name of the column The plot labels should be extracted from the file. If I request a plot between column 1 (crank angle) and column 8(volume), then…

Simulink model: Powertrain subsystem: Engine block: Vehicle dynamics block:   REPORT: The fuel economy numbers (kmpl) for UDDS and HWFET cycle: Drive Cycles Fuel Economy [kmpl] UDDS 14.2044 HWFET 16.5010   Vehicle characteristics time trace: UDDS cycle: Observation:  In the 1st plot, we could see a constant…

1. What does popt and pcov mean?  The curve_fit function returns two items, which is popt and pcov.  popt - The popt arguments are the best-fit parameters. It is an array of optimal values for the parameters which minimize the sum of squares of residuals. pcov - The pcov variable contains the covariance matrix,…

Double-acting actuator model: The input data for building the model was taken from the reference. But the input signal was modified in the Signal builder block to move the actuator up and down to understand the multibody model better.   Model: Hydraulic Cylinder Assembly: Subsystem: Double Acting Hydraulic…

Objective: To write a program that solves the simple pendulum ode and animate the solution.  Solution Procedure: Input data: b=0.05   g=9.81  in m/s2 l=1    in m m=1 in kg   Simulation is done for 0-20 sec, for angular displacement=0,angular velocity=3 rad/sec at time t=0.   Modifying…

Objectives: To solve the otto cycle and plot the PV diagram and also calculate the thermal efficiency of the engine. Parameters: Inlet Pressure, p1=101325 Pa Initial Temperature, t1=500 K gamma=1.4 Geometric parameters: bore=0.1 m stroke=0.1 m Connecting rod length, con_rod=0.15 m Compression ratio, cr=12   Temperature,…

Project: Speed Control of a DC motor DC motor Parameters: J=0.01; %Moment of Inertia of the rotor-kgm^2 B=0.1; %Motor viscous friction constant-Nms Km=0.01; %Back EMF constant-V/rad/s Kt=0.01; %Motor Torque constant-Nm/A Ra=1; %Armature resistance-ohm La=0.5; %Armature Inductance-Henry   PID Design: Basic eqn: u(t)…

Project: >> VI=xlsread('VI.xlsx'); %loads excel data>> V=VI(:,1);  %1st column of VI is assigned to V>> I=VI(:,2);   %2nd column of VI is assigned to I>> xq=[-17.3:0.1:0.9]; >> yq=interp1(V,I,xq);  %interpolating for the given range>> figure(1);>> plot(V,I,'o',xq,yq,':.');grid; …

1. Major elements Battery  fuse ammeter current and voltage regulator junction block ground generator switches breaker starter distributor 2. Three elements Fuse - It is used to protect the wiring and electrical components from short circuits or overload. When excessive current flows through the circuit, huge amounts…