Week 1:- Introduction to BiW and Fixtures Challenge

            DESIGN OF AUTOMOTIVE MECHANICAL WIRING HARNESS FOR ENGINE   Master’s Manufacturing Design   By Avvaru Hari Tej Skill-Lync   APRIL 2021   Table of Contents Table of Contents. i 1        INTRODUCTION.. 1 1.1      …

DESIGN OF WIRING HARNESS FLATENNING IN CATIA V5 INTRODUCTION The wiring harness flattening consists of assembly of geometrical bundle to form a flatten bundle to get the 2D drawing details. For the mechanical wiring harness, assembly of geometrical bundle is the main component. In the present project, the wiring harness…

DESIGN OF WIRING HARNESS ROUTING IN CATIA V5 INTRODUCTION The wiring harness routing consists of assembly of geometrical bundle and electrical bundle. For the mechanical wiring harness, assembly of geometrical bundle is the main component. For assembly of geometrical bundle, the connectors, clips, grommets must be electrically…

DESIGN OF WIRING HARNESS ROUTING IN CATIA V5 INTRODUCTION The wiring harness routing consists of an assembly of the geometrical bundle and electrical bundle. For the mechanical wiring harness, assembly of the geometrical bundle is the main component. For assembly of the geometrical bundle, the connectors, clips, grommets…

DESIGN AND ASSIGING ELECTRICAL PROPERTIES TO CLIPS, BACKSHELL, CORRUGATED TUBES AND INSULATION TAPES IN CATIA V5 INTRODUCTION CLIPS: This is the important component of the wiring harness which would be defined before wiring harness routing. Clips accumulate the bundle in the amended position. The main points and planes…

WIRING HARNESS DESIGN IN CATIA V5 INTRODUCTION Wiring harness is the combination of electrical and mechanical CAD to connect all the electrical parts in the automotive at the optimum level. BASICS OF ELECTRICAL DISTRIBUTION SYSTEM (EDS) AND WIRING HARNESS 1) Electrical Distribution System: It runs from front end to rear…

BOM : 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. In a nutshell, it is the complete list of all the items that are required to build a product. BOP : A bill…

2D DETAILING OF CLAMP AND PIN UNITS INTRODUCTION The fixture design before going to the manufacturing department needs to be detailed clearly and accurately. All the dimensions to fabricate the fixture units have to mention in the drawing sheets. There are different drawing sheets available as per the company requirements.…

2D DETAILING OF FIXTURE UNITS INTRODUCTION The fixture design before going to the manufacturing department needs to be detailed clearly and accurately. All the dimensions to fabricate the fixture units have to mention in the drawing sheets. There are different drawing sheets available as per the company requirements. As…

1) What are Drawing templates? Ans) a) Drawing templates are basically the drawing standards as per customers specifications. b) They are formats that are used for detailing of different parts or units of the fixtures. c) There are ‘n’ number of details that are already available on the template and are useful…

DESIGN OF FIXTURES FOR CAR PANEL 1) INTRODUCTION The fixture is a device used for holding and positioning of panel, locating and setting of the tool but no guidance will be given to the tool. The fixtures are the units that are used to constrain the car panel in the manufacturing process. The fixture design consists the…

1) What do you understand by the 3D finish process? 2) What are the points need to be taken care of while finishing the design? Ans: 3D finish is the process where design is completely finished and to be ready for final simulation and 2D detailing. Points to consider: a) Hole concentricity and sizes has to be check for…

DESIGN OF FIXTURES FOR CAR PANEL 1) INTRODUCTION The fixture is a device used for holding and positioning of panel, locating and setting of the tool but no guidance will be given to the tool. The fixtures are the units that are used to constrain the car panel in the manufacturing process. The fixture design consists the…

What is the Base Unit? What are the typical parts of the Base Unit? Ans: A Base unit is a unit designed to mount all the other units(Clamp, pin, rest units) of the tool, also other parts necessary for a tool like pneumatic valve box, trunking cable path will be mounted on to the base unit. Parts of Base Unit: Trunking…

DESIGN OF SWIVEL CLAMP UNIT INTRODUCTION A Swivel Clamp unit is a unit designed to clamp/hold the car panel with NC blocks/ Mylars/ Rest by using a swivel cylinder. The parts of the clamp unit are: Rest block /Mylar L - block Shim / spacer Blade or Adapter plate Riser. Clamp Arm Swivel cylinder FUNDAMENTAL OF CLAMP UNIT:…

DESIGN OF CLAMP UNIT INTRODUCTION A Clamp unit is a unit designed to clamp/hold the car panel with NC blocks/ Mylars/ Rest by using a pneumatic clamp cylinder. The parts of clamp unit are: Rest block /Mylar L - block Shim / spacer Blade or Adapter plate Riser. Clamp Arm Pneumatic cylinder FUNDAMENTAL OF CLAMP UNIT: Take…

DESIGN OF FIX PIN AND RETRACTABLE PIN UNIT INTRODUCTION The fix pin and the retractable pin units are hole constraining fixtures for car panels. FIXED PIN UNIT: Fixed pin unit is a unit designed to locate the car panel using pins. The parts of fixed pin are: Pin Pin retainer Shim / spacer Block Blade or Adapter plate Riser.…

1.What is Design Methodology? Ans: Design methodology is the steps followed during the concept designing stage of fixture design. The steps in design methodology are: 1. Purchase order: The purchase order is the document received from the customer which gives the details of the product, time plan. 2. Inputs from customer:…

1.What is the process of project execution activity? Ans:  1.RFQ: RFQ stands for request for quotation. Once the RFQ is received from the customer, need to study the RFQ and prepare the documents of technical information, production information, time duration to manufacture. 2. The 1st spec Discussion meeting…

1.What is BIW & define its parts? Ans. BIW stands for the body in white. Body in white (BIW) is the stage in automobile manufacturing in which a car body frame has been joined together, that is before painting and before the motor, chassis sub-assemblies have been integrated into the structure.   BIW is sub-divided…

BACK DOOR DESIGN 1        INTRODUCTION The back door or tailgate is in the back portion of the car, where luggage and spare parts are being stored. The cars are defined based on the car's back door as a sedan, hatchback, coupe. 2        DESIGN IN NX…

ROOF DESIGN USING NX CAD 1        INTRODUCTION The roof is the top layer of the car, which protects the passengers from the sunlight, rain, and wind. The roof consists of a front roof rail, bow roof, center roof reinforcement, and rear roof rail. The bow roof is used in the flat section…

SECTION MODULUS CALCULATION 1        INTRODUCTION SECTION MODULUS is the ratio of total moment resisted by the section to the stress in the extreme fiber. It gives an idea of how much load a structure can withstand if section modulus increases the moment of resistance increases, and hence…

FENDER DESIGN USING NX CAD 1        INTRODUCTION The fender is the side frontal portion of the vehicle, which protects the pedestrians from small dust particles. There are five mounting regions in the fender Bumper mounting A-pillar mounting Sill mounting Splash mounting Drip mounting…

HOOD DESIGN USING NX CAD 1        INTRODUCTION HOOD: The hood is the cover of the engine in the vehicles with an engine at its front. The hood has two panels one is the outer panel, and the other is the inner panel. The outer panel design depends on the aerodynamics and car style. The…

UNDERBODY COATING UNDERBODY COATING: 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. Modern Automotive Coating Processes Modern…

MOLD DESIGN FOR CPU FAN BEZEL 1        OBJECTIVE The objective of the present project is to model a mold consists of a cavity block, core block along with sliders, inserts, ejector pins, ejector plates, sprue gate for the CPU fan bezel. 2        PROCEDURE…

BENCHMARKING 1        INTRODUCTION BENCHMARKING: Benchmarking in the automobile industry involves a structured comparison between similar products, services, or processes on some dimensions of performance. For example, it can be used to compare the availability and delivery of features…

MOLD DESIGN FOR TABLE FAN BASE 1           OBJECTIVE The objective of the present project is to create a mold for a table fan base using SOLIDWORKS. 2.          PROCEDURE STEP 1: Detecting the direction of cavity and core regions. As a long projection is towards the…

COOL ANALYSIS OF RULER GEOMETRY1         INTRODUCTIONThe cool analysis in the MOLDFLOWgives significant results. It helps the analyst to check the part deflections and other inaccuracies that occurred in part. By this data, the analyst can improve the cooling circuit design accordingly…

MOLD FLOW ANALYSIS OF A HANDLE USING NYLON6 MATERIAL 1         INTRODUCTION The handles are essential components in automotive and engineering applications. In industry, if a has to be lifted from one department to another, handles play a crucial role. In vehicles like buses, handles…

1         GATING SYSTEM 1.1         OBJECTIVE The objective of the present challenge is to create a complex gating system for a thin part ruler accompanying 8 molds. The same has to be done using the occurrence number option and compare the results obtained.…

INTRODUCTION TO AUTODESK MOLDFLOW OBJECTIVE Learning the window of AutoDesk Moldflow. Learning the tools which are used to create a geometry. Learning to mesh the workpiece accurately and without any errors using dual-domain mesh. PROCEDURE Two parts are generated in MOLDFLOW, and one is with the same dimensions as described…