Week 1:- Introduction to BiW and Fixtures Challenge

 PROJECT 1 ENGINE WIRING HARNESS Aim:- To Design Wiring Harness for Given Engine Data. Obective : To Design Wiring Harness.  To Define Connectors Electrically. To Route the Electrical Bundles by using Connectors,P Clamps,Firr Tree and Guide Channel. Flatten the Harness and Drafting for Manufacturing.  INPUT…

WEEK 01 CHALLENGE What is full form of OEM?  OEM means original equipment manufacturer as for the any kind of industry they will have a responsibility of manufacturing the crucial parts or any vital part in their product in their house for instance: Ford OEM parts, this means that all parts are made specifically…

PROJECT_C  Aim: to Design Fixture for the given panel data  performing 3D finish, 2D detailing and Documentation for the fixture . 3D Finish is a process where the design is being completely finished and to be ready for final simulation and 2D detailing. while finishing the design the nominality is checked which the easy…

AIM:  To create the BOM and Hardware list(BOP) for the complete Fixture assembly. BOM : (Bill Of Material) A bill of materials – BOM – is the full list of every item necessary to build a product. It enumerates all parts, assemblies, subassemblies, raw materials, and components that building the product…

2D DETAILING CHALLENGE 2 1.CLAMP UNIT 01 CLAMP UNIT ASSEMBLY    1.RAISER 2.L BLOCK 3. PIN RETAINER 4. PIN   5. CLAMP FINGER    6. CLAMP MYLAR   7. REST MYLAR     2. CLAMP AND PIN  UNIT  CLAMP AND PIN UNIT ASSEMBLY   1. RAISER   2. REST MYLAR   3. CLAMP MYLAR…

PROJECT_B DRAFTING               FIX PIN UNIT ASSY RAISER L BLOCK PIN RETAINER PIN SHIMS   CONCLUSION Draft a Key Sheet for the Complete Fixture assembly created in challenge 8. Draft a Base Unit and the Fix Pin Unit drawings with all child parts for the complete Fixture assembly from challenge 8      

What are the Drawing templates? Answer: First of all let we know about some basic definition of drawing. Drawings (A graphical representation): If compared with verbal or written description, drawing offer far better idea about the shape, size & appearance of any object or simulation or location, that too in quite a less…

Aim:- To create Rough locator for the fixture. To Perform 3D finish for all units by considering manufacturing fesibilities. Introduction :- ROUGH LOCATORS A rough locator is a part designed to guide the operator, to locate the car panel on to the pins accordingly. A rough locator can be of standard part or make part.…

1) 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…

BASE UNIT DESIGN 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…

1. What is the Base Unit? What are the typical parts of the Base Unit?        Base unit is one of the main units in a BIW Fixture. A Base unit provides the platform to mount all the other units like rest units, clamp units and pin units etc. Base unit also mounts the components like Valve…

DESIGN OF CLAMP UNIT AND PIN-CLAMP UNIT OBJECTIVE: To design 3 types of Swivel Clamp unit and 1 Pin-Clamp unit with different Riser, Blade and Clamp arm while maintaining the stroke of cylinder as 100mm. ABSTRACT: In automotive industry, a lot of processes are followed to make a single panel and further operations are…

Rest Unit & Clamp Unit Design Challenge   Aim- To Design 3 Different types of Power Clamp Unit with Different Riser, Blade and Clamp Arm for the given Car Panel and Design 2 Different types of Rest Unit for the given Car Panel. Rest Unit: Rest unit is unit designed to support car panel using Mylar/ NC…

PIN UNIT    OBJECTIVE -  1) Design two different types of fixed pin unit with different pins , pin retainers , blocks , blades , risers .  2) Design two different types of retractable pin unit with different pins , pin retainers , blocks , blades , risers .    INTRODUCTION - …

  1.What is design Methodology? Design methodologies are the steps that are followed during the concept designing stage of the fixture. a.Purchase Order(PO) The purchase order (PO) is the official document received from the customer. which commits the customer to pay the seller for the sale of a specific product to be…

  What is the process of project execution activity? Project activities are those basically are being processed or being practiced in general project of BIW begins. Project activities are task from start to end of project. There are various step involved in project. Below fig. show flow chart of project activities.…

 Introduction to BiW and Fixtures Challenge 1.What is BIW & define its parts?   BIW (Body in White) refers to the welded sheet metal components which form the vehicle structure to which the other components will be married, i.e., chassis, exterior trim, interior trim, & engine. Here the structure is unpainted. The BIW…

    Wiring Harness Routing of Back Door Panel of a Car In this challenge, we will perform the Wiring Harness Routing of a Back Door Panel and at the end will prepare a flattened view drawing for the same. All packaging rules & the best industry practices will be followed during this process. The steps…

AIM:-  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. OBJECTIVES To design Harness Flatten using Exisisting Wiring harness To draft the Harness Assembly as per production…

  AIM:- To route the Harness layout in Eletrical workbench by using the connectors which taken as an inut Objectives: To Check the Bundle Connectivity. Adding Annotations to connectors. check for bundle warning Generate CATPart and make STP or IGS File...   INPUT We have to route the harness as shown in below…

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)   HARNESS LAYOUT  …

  SUPPORT DEFINITION   P Clamp  link: https://drive.google.com/file/d/1cL9NiCnMl1I0SGlRESUZwdjSP5_9eAlb/view?usp=sharing P Clamos are used to clamp the Wiring Harness by providing rubber insulation in order to protect from Electrical Short circuits and damages In clips there are 2 entry faces and 2 exit…

  Q1. 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    1.) Step– 1 :- CREATE / DOWNLOAD CONNECTOR 3D The connectors to be defined…

Development of a Door Trim panel   Creation of CAD model considering following inputs as like in OEM and tier1 companies a) Class A surface b) Nominal thickness : Refer master sections c) Attachment strategy :  Find a attachment strategy for the door panel complete work. Use Push pin with Dog house for Lower…

Week 10- Assembly Workbench Aim : To create Assembly for Given 2D Drawing and Drafting  QUICK RETURN MECHANISM PARTS  MAIN FRAME BLOCK SLIDER DHAFT ARM MAIN FRAME Sketch Thickness sketch Pad BLOCK  Sketch Revolve ARM Sketch MULTI PAD SLIDER  Sketch Sketch   Pad SHAFT ASSEMBLY  DRAFTING  …

Project - A pillar Design with Master Section  Aim: to create A pillar By using Class AA surface Objectives: CLASS A SURFACE Class A Surface of A pillar is given we need to check for Quality of the given surface by using Boundry feature if there are any patches left we havve to modify the given surface. Check for…

 Project_1 - Door Trim Lower with Engineering Features Aim : To create B Side Engineering Features for Given Class A Surface. OBJECTIVES: Creating Tooling Axis with proper draft. Creating Surfaces (B&C) Creating B side Engineering Features i.e Heat Stakes and 4 way locators as shown in the sample figure. Draft…

Attachment Feature Creation - Challenge 2 Aim:- To Create Dog House Feature for given Class A Surface. Objectives: Thickness is 2.5mm. Draft analysis. creating Dog House Considering Design Rules Design Rule for Dog House  Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than…

Attachment Feature Creation (Ribs & Screw Boss) - Challenge 1 Aim:To create B side feature Ribs and  Screw Boss for given Drill Handle Class A Surface by considering Design Rules.  DESIGN RULE FOR RIB  DESIGN RULE FOR SCREW BOSS General Guidelines for Bosses:   Draft  - 0.5 degrees on…

Challenge 5 - Door Trim Lower Aim: To create Door Trim Using Class A surface OBJECTIVE :- Create the Door Trim Plastic component through the given Class-A surface. Thickness is considered as 2.5 mm Creating Tooling Axis. Performing Draft Analysis. For Class A Surface  For CLOSED PART     CLASS A SURFACE this is a class…

Challenge 6 - Core & Cavity Design Aim: To create core and cavity block for switch Bezel considering all plastic design rules. Steps Followed: Creating parting Surface Creating Core Side Creating cavity side.      Parting Surface: Generally, injection mold has two major components: the movable…

Challenge 4 - Bumper Aim: To Create Bumper Using Class A Surface.   CLASS A SURFACE   Class A surface is the outer most surface of the component, it is an aesthetic surface. It is also called as Strak. As a designer we don't have rights to  modify the class A surface without permission.                      Then we have…

Week 8 - Challenge 3 - Coin Holder Design AIM:- To Create Coin Holder Plastic Component through given Class A Surface Objectives:- To create Tooling Axis. To Create Class B Surface. To create Class C Surface. To create Closed Surface and create Part Model    CLASS A SURFACE TOOLING AXIS CREATION For Creating…

Week 8 - Challenge 2 - Switch Bezel Design Aim:- To Create the Switch Bezel Plastic component through the given Class-A surface. Objectives: Create Tooling axis with the Class A Surface. Check For the Draft by tooling axis. To Create Class B Surface. To Create Class C Surface. To create model With Closed Surface Feature.…

 Week 8 - Challenge 1 - Base Bracket Design  AIM:-  To create a Base Bracket Plastic Component using a Class 'A' Surface and by using the Closed Surface Feature to create a solid part from the surface. OBJECTIVE:- To create a Plastic Surface Using Class A surface. To create Tooling Axis for…

 BENCH MARKING Bench marking is method of comparing the already existing   vehicle of our own model with the models of compotators, and analyzing the end results and making detailed report.. this report will contain all the necessary data that needed to compare with ours. By this method we can get to know…

OBJECTIVE:                      To design a Backdoor (Tailgate) of car by adding reinforcements to its assembly parts using CATIA V5.   INTRODUCTION: BACK-DOOR/TAILGATE:                     A door is a hinged part used for entry and exit of the vehicle.Back-doors are one of the types of doors which are located next to…

Aim:  The main aim is to determine the heat distortion criteria,snow load criteria and draft analysis. 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 other external elements. Safety point of view…

Objective:-To design the Front fender using CATIA V5.   Introduction: 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 tomprevent sand,mud,rocks,liquids and other roads spray from being thrown…

OBJECTIVE:-  calculate the wheel arch area and prove whether the car will pass the european standards or not.   Different F ender regulations there are 3 types of regulations 1. Japan regulation 2.European regulation 3.US regulation   1. Japan Regulation      For the calculation purpose…

SECTION MODULUS Section moduluds is a geometric property for a given cross section used in the design of beams or flexural members. It does not represent anything physically. To define section modulus, it may be defined as the ratio of total moment resisted by the section to the stress in the stress in the extreme fiber…

Title - Hood Design   Objective  Design of Hood By considering given data of outer pannel and master sketch.   Hood is basically one type of door which is used to close the engine compartment. Hood consists of two mair parts inner panel and outer panel where inner panel givws strength to outer sheet and outer panel just…

UNDERBODY COATING  Underbody coating is the type of coating which is used for automobiles to improve its corrosive resist properties. It's also used to with stand impact loads such as stones which may result in peal off paint resulting in corrosion.  undercoating is protects from rust and acts as anti rust agent.…

 BENCH MARKING Bench marking is method of comparing the already existing   vehicle of our own model with the models of compotators, and analyzing the end results and making detailed report.. this report will contain all the necessary data that needed to compare with ours. By this method we can get to know…