Week 1:- Introduction to BiW and Fixtures Challenge

*Assembling Butterfly Valve Components.   Isometric View:     Front View:       Side View:       Top View:              

    AIM: To create a BOM and Hardwarer list (BOP) for the complete fixture aasembly from challenge 8. PROCEDURE: Bill of materials is basically a file, which includes all the information required for the assembly of printed circuit boards. It is one of the most important things required while manufacturing PCBs. Failure…

  OBJECTIVES: 1. Create 2D Drawing for Clamp Unit with all child parts. 2. Create 2D Drawing for Pin Unit drawings with all child parts.       CLAMP UNIT:                         PIN UNIT:          …

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.   DRAWING RESULTS : Assembly:     BASE UNIT:        …

  1. What are drawing templates?   Compared to conveying data in verbal or written form, symbols and drawing provide information in a better and more understandable way minimizing errors caused by miscommunications or misunderstandings. Drawing templates are standards decided by the client.  Drawing templates…

*Designing Rough Locators for the given BIW Panel.     Given Panel:       3D finish is the process where design is being completely finish & to be ready for final simulation & 2D detailing Following points are taken into consideration while finishing the design:- Hole concentricity &…

    1. What do you understand by the 3D finish process? Ans:  While finishing the design the nominality of holes is checked which ensures easy assembly of all the units. The hole concentricity and hole sizes are checked which ensures the easy assembly of different parts. The gaps between the different units are checked…

*Designing a Base Unit for a BiW Fixture Units.   Given Panel:         INTRODUCTION The base unit is designed to mount all the other units like clamp unit, pin unit, rest unit, etc of the tool, also other parts like pneumatic valve box, trunking cable path will also be mounted on the base unit.…

  1. 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:…

*Designing Clamp Units with Swivel Cylinders for a BIW Fixture.     Given Panel:     Two types of Clamp units used to clamp the car panel. They are: Power Clamp Unit. Swivel Clamp Unit. To weld these parts ,they must be fixed using 3-2-1 principle: 3-2-1 PRINCIPLE:   Fixture must correctly locate a workpiece in a given…

*Designing Rest & Clamp Unit for a BiW Fixture.   Given Panel:       Introduction: Rest Unit: Rest unit is a unit designed to support a car panel using Mylar/ NC block/ rest component is rested only, no upper clamp or force applied there. It is the simplest unit to design because it has…

*Designing different Pin Units for locating a panel in a BIW Fixture.   Given Component:     Types of Pin Units: 1. Fixed Pin Unit. 2. Retractable Pin Unit.   FIXED PIN UNIT Fixed pin units are used in a fixture to locate the car panel during any operation. RETRACTABLE PIN UNIT Retractable pin unit…

1. What is Design methodology ? Design methodology consist of Four stages: 1. Purchase order. 2. Inputs from customer. 3. Percentage completion criteria. 4. Design Output.   Purchase order: - It is the first official document that we will receive from customer side, this document will basically give confirmation to…

1. What is the process of project execution activity? Performing the activities needed to meet the project Obtaining and manage quotations, bids and proposals as needed. Managing the project team and manage other resources. Collecting and analyse performance data. Generating project data…

  1. What is BIW & define its parts? In the automobile industry, BIW (Body in White) is a general term used to refer to welds (body) related to sheet metal in automobiles. In today's situation, car BIW is made of steel (various types of steel DP, DD, HDP, etc.) as well as aluminium alloys. Subassemblies such as…

*Developing Car Back Door by Using given Styling Surface Method by Automotive sheet metal design. Tool Used :- CATIA V5.   Introduction :      Design of back door is also called as the Tail gate. A car back door which is consist of Inner panel, Outer panel. Basically the car parts are made of Steel…

*Designing the front roof rail, rear roof rail, and bow roof for the roof to the vehicles with the help of the given skin data of the roof.   Roof: An automobile roof or car top is the portion of an automobile that sits above the passenger compartment, protecting the vehicle occupants from sun, wind, rain, and…

Aim :- To calculate the section modulus of the previously designed hood for analyzing its strength and also optimizing the design to see the difference in the bending strength of the hood.Higher the section modulus of a structure,the more the resistive it becomes to bending.     Section modulus :- Section modulus…

  *Calculating Wheel Arc area and proving whether the car will pass the European standards or not.   Wheel Arch: Wheel Arch is the semi-circular part of the fender positioned above the wheel of the vehicle.  The design of Wheel arch of a fender should be such that it must shield wheels and protect both passengers’…

*Designing Front Automotive Fender.   Given Input:         Introduction:- The design of any product starts from a requirement.The design engineer sketches the product based on the requirement. Then the 2D sketch with the proper dimensions is converted into the 3D model using the advanced CAD software.Another…

*Designing sheet metal structure of Hood from the given Input Surface.   Given Surface:         Data to be used: Hood Thickness Information Outer Panel Thickness = 0.75mm Inner Panel Thickness = 0.75mm Reinforcement Thickness = 1.5mm Master sketch:       Objective: To understand…

UNDER BODY COATING:   We all are aware of the fact that the underbody of the previous models was made from durable metals such as steel, which is easily damaged and oxidized, forming rust While you are sitting on the driving seat enjoying the smooth ride, the underbody of your car is always exposed to muddy water,…

AIM:  To create the automotive door trim panel from the given class A surface and a thickened part with the required features to locate, mate and assemble the components.   OBJECTIVE: The door trim panel with the necessary surfaces developed along with the engineering features on the B side surface that…

Aim: To expain about Benchmarking and finding a good car for Mr.D.S.Pughazhyendhii by comparing the cars.   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, “best in class.”…

    4 Bar Quick Return Mechanism: First we have to create the all parts of this mechanism and then assemble this.     Creation of First part: Create the required sketch according to the given dimension. Then pad it     Creation of second part:     Creation of third part:    …

    AIM: Design B-Pillar through master section Development.     Step 1:  Create a tooling axis.For creating the tooling axis first we extract these 4 boundaries. Took a point between these 2 lines. then draw a bisecting line between these two-line by using point. again bisect the remaining…

AIM: To create Plastic design and attach the Engineering features and generate the Draft Analysis for the given Door Applique Class A model. DOOR APPLIQUE DOOR ATTACHMENT SURFACE PROCEDURE: 1.Check for any openings in the given model Door Applique by using BOUNDARY. In BOUNDARY > select edges - select…

*Creating Screw Boss & Dog House for Centre Console Coin Holder.       Given PartBody:       ScrewBoss: Screw Bosses are components which are present at the B-Surface. They attach to other components with the help of screw bosses. They are commonly found on injection molded components.…

 *Creating Ribs for the given PartBody.       Ribs Guidelines:         Given PartBody:         Creation of Ribs: Step-1: Extract the top surface on which the ribs have to locate. Take a mid point to it and also do sketch to it.         Step-2:…

*Creating Core & Cavity Blocks for a PartBody.     Core Block: Core Block is a block which is present below the plastic component which acts as a mold to the component. It is a fixed block in the injection molding machine which has ejecting system.   Cavity Block: Cavity Block is a block which presents…

*Creating PartBody using Class-A Surface.     Given Class-A Surface:         Creation of B Surface: Step-1: First make a tooling axis to the model. Extract the base surface. Insert a middle point on it and make a perpendicular line to it. Make that line as your main tooling axis.    …

*Creating PartBody using Class-A Surface.     Given Class-A Surface:       Step-1: Step-1 is make a point for the main tooling axis to check the comnponent is manufacturable or not. So, take a point in the hole and insert an axis system and make a tooling axis for the component. Also take a side…

*Creating Class-B & Class-C Surfaces using Class-A Surface and Performing Draft Analysis on it.       Given Class-A Surface:       Step-1: Step 1 is to make a tooling axis for your model unless it doesn't exist. Tooling axis should be considered parallel where many surfaces are present.…

*Creating B & C Surfaces with the refrence of Class A Surface.     Class-A Surface: The top-most surface which is present exterior of the component is siad to be a 'Class-A Surface'. Class-B Surface: The Surface which is interior to the component is said to be a 'Class-B Surface'. Class-C Surface: The…

*Creating tooling axis for the given model & Performing Draft Analysis on it.    Draft Analysis:                          Draft Analysis is an analysis technique which lets us know whether the component (plastic or sheet metal) is manufacturable…

*Answering the following conditions:   Implement control logic of a “washing machine” using Stateflow as per given sequence: Conditions:    - If the power supply is available, the system gets activated.    - If the water supply is not available, stop the process & indicate through…

Aim: Create a doorbell model using solenoid in Simulink. Build a model using thermister to sense the temperature.     1. Doorbell Model:                                       Here, Doorbell consists of the main parts…

File Parsing:   In MATLAB, File parsing is generally used to read or write data to any file. It can be either in '.txt' or '.dat' or any other file containing data.   Commands used for file parsing: 1. fopen - open file, or obtain information about open files.         syntax: fileID = fopen(filename,permission)…

 Genetic Algorithm (stalagmite):   Aim: To show how the global maxima obtains in stalagmite function using 'Genentic Algorithm'. Plotting graphs to show how the function maximum changes with multiple iterations.   Theory: In genetic algorithm, generally the term 'Algorithm' refers, Algorithm:    …

SECOND ORDER ORDINARY DIFFERENTIAL EQUATION (ODE): ORDINARY DIFFERENTIAL EQUATION (ODE):                                                                  …