Week-11 Challenge: Braking

Introduction: When thermoplastic components are involved in the assembly, they are required to be joined with a dissimilar material. The material with which it is assembled could be a metal or a other kind of thermoplastic material. The joining is facilitated by heat staking. Thermal staking is an assembly process which…

Introduction: A-pillar is an important structure of the four-wheeler vehicle. It supports the windshield and roof. It is the first pillar of the vehicle. It connects with the windshield frame, provides groove to the window and connects with the roof. In this project, Class-A surface of the A-pillar is taken as input and…

Draft Analysis of an Automotive Bumper Plastic Component:  Introduction: A bumper is an automobile's front part that shields the engine and provides housing for headlamps and defogging lamps. It is a plastic component and is manufactured by Injection Moulding Machine. Hence the component needs to be verified if it…

Introduction: To create attachment features on the door handle part. The attachment features include ribs and dog houses.  Procedure: 1. The image below shows the Class A surface of the door handle. Cursory look at the part reveals that the tooling axis is along the Y-direction.  2. Tooling axis is created …

Core and Cavity design Introduction: The acitivity involves design of core and cavity for Switch bezel component. The Class A, B and C surfaces are used to form Core and Cavity. Cavity: Cavity is the fixed half of the injection moulding machine. It consists of runner and gates through which molten plastic is injected into…

Switch Bezel Design Introduction: The project aims to create a automotive plastic compoenent: Switch Bezel. The class A surface is the input for the project. The given surface is analysed to ideate on the tooling axis based on the direction the part could be ejected from the injecion moulding machine. The tooling axis…

Base Bracket Design: The base bracket design process involves creation of the tooling axis for the given class A surface, performing draft analysis for class A surface, creation of class B and class C surface, trimming all surface together and closing the surface to create solid body.  Tooling axis creation: Class…

Draft analysis of Automotive Coin Holder Introduction: The plastic components are manufactured using an Injection Moulding Machine. The machine consists of core and cavity, the male and female components that integrate into each other with gap between them equivalent to the thickness of the part required.  The mould…

Draft analysis: The above image shows the plastic component: Fan cover. The component is designed using surface modelling techniques. Before the thickness is alloted to the surface to form solid part, draft analysis needs to be performed.  1. Initially, it is made sure that the surface model of the fan cover does…

 Aim:  To perform geometry clean-up, mid-surface extraction and mesh generation on the half part of Instrument Panel of four-wheeler vehicle adhering to the following quality criteria:   S.No  Quality Criteria  Value  1 Target/Average length   4 2 Minimum Length  2 3 Maximum…

Problem statement: Create a Rankine Cycle Simulator using OCTAVE/MATLAB. Your code should calculate the state points of the Rankine Cycle (any type of your choice) based on user inputs.  Then, plot the corresponding T-s and h-s plots for the given set of inputs. Title and axes labels are a must, while legends could…

Title: Design of Sheet Metal Bracket including Advanced Flange and Gusset features in Siemens NX Objective: To model the flange with right features and parametric values in Sheet Metal application To understand advanced flange and gusset feature  To capture the images of th final model in various standard orientation …

Title: Design of Bracket using Siemens NX Objective: Modelling the base of the bracket using contour flange in sheet metal application Creating the flat pattern of the bracket and importing it in the Draft application and obtaining 2D engineering drawing for the bracket Introduction: In the process of sheet metal modelling,…

Title: Design of Sheet Metal Odd Shaped Enclosure in Siemens NX Objective: Modelling the enclosure as a solid component to generate a general enclosure layout Converting the solid to sheet metal and adding required features to the unbend version of the enclosure in Sheet Metal application Drafting the 2D engineering drawing…

Title: Design of the Sheet Metal Box Assembly using Siemens NX Objective: To layout the procedure to form the Box Assembly To follow the procedure and use appropriate features and commands to accurately model the part in Siemens NX To capture and attach various standard views of the final model   Introduction:…

Title of the Project: Design of Sheetmetal Casing using Siemens NX Sheetmetal Application    Objective: To model the sheet metal casing in Siemens NX by using appropriate commands  To obtain isometric and various orthographic views of the model To create the draft of flat pattern of the sheet metal casing…

Title: Surface Modelling of Sunseeker Predator 108 Yacht in SolidWorks  Objective: To model various parts of Sunseeker Predator Yacht individually in part files  To assembly all the parts with appropriate mate conditions in the assembly file To produce renders of the Yacht parts and assembly using appropriate…

Title of the Project: Modelling of American chopper in SolidWorks using bottom-up approach, assembling all the parts using appropriate mate conditions and rendering photo-realistic images of the two-wheeler using SolidWorks Visualize.     Objective: Modelling all the parts of the American chopper in SolidWorks…

Aim:  To check for geometrical errors and obtain clean topology for the Rear Suspension model. To identify shell and solid components and components with uniform and non-uniform thickness and mesh them with appropriate meshing techniques and considering the quality criteria. To deploy the connections between various components…

Aim: To perform morphing on the components and discuss the industrial application of morphing Theory: Morphing is a process of reshaping products.  In automotive industry, the development time has shortedned from 7 years to 5 years and further shortening. The development cycles are rapid and new cars are launched…

Aim: To deploy suitable connections on the given rear door FE model in ANSA  Procedure: The image shows the isometric view of the rear door FE model.  Deploying bolt connections: Using RBE2 function  RBE2 defines a rigid body element of form 2. This element is a rigid body with independent degrees of freedom…

Tool Test 2: The intake manifold is meshed with Ortho trias on the curvy surfaces and normal trias on plane surfaces with 0 quads. The volume mesh is performed with tetra FEM algorithm. There are no quality failures. 

Aim: To check for the geometrical errors of the rearview mirror and mesh the surface of the component with 2D elements conforming to the following criteria:   S.No  Quality Criteria  Value  1 Target/Average length   1 2 Minimum Length  0.5 3 Maximum Length  2   And to mesh the…

The tool test models are attached.

 Aim: To check for the geometric errors, extract the mid surface with suitable technique and perform meshing on the plastic bottle cap with the following quality criteria:   S.No  Quality Criteria  Value  1 Target/Average length   1 2 Minimum Length  0.5 3 Maximum Length  3…

 Aim: To take the mid surface for all the components for the given hood model after checking the geometrical errors and mesh the mid surface with the given element Quality criteria as mentioned below:  S.No  Quality Criteria  Value  1 Target/Average length   5 2 Minimum Length  2 3 Maximum Length  7 4 Aspect  3 5 Warpage…

Aim: To design a battery pack with an enclosure of a capacity of 18 kWh using ANR26650M1-B cell Theory:   This cell is based on Lithium Iron Phosphate chemistry. The cell is capable of delivering high power with the use of patented Nanophosphate technology. This enables the cell to work optimally in wide temperature…

Problem statement: 1.Simulate the 3 test cases from the harness dashboard and write a detailed report on the results of the simulink file: https://in.mathworks.com/matlabcentral/fileexchange/72865-design-and-test-lithium-ion-battery-management-algorithms 2.What is coulomb counting? Refer to the above model and explain…

Problem statement: 1. Prepare a table that includes materials & chemical reactions occurring at the anode and cathode of LCO, LMO, NCA, NMC, LFP and LTO type of lithium-ion cells. Give your detailed explanation on it 2. Compare the differences between each type of Li+ion batteries based on their characteristics Solution:…

Aim: To create a MATLAB model of an electric rickshaw having rear wheels driven by Permanent Magnet Brushed type motor with assumed efficiency points of motor controller and motor. And to simulate the model for three standard driving cycle while tracking the battery energy consumption, motor and controller temperature…

Problem Statement: Part A: 1. Search and list out the total weight of various types of aircrafts.  2. Is there any difference between ground speed and air speed? 3. Why is it not recommended to use aircraft engine power to move it on the ground at Airport?  4. How an aircraft is pushed to runway when its ready…

Problem statement: For a defined driving cycle, calculate the energy required for braking. Why electric motor can’t develop braking torque at high speed similar to starting? How electric and mechanical brakes are coordinated?  Make a MATLAB program which plots contour of given motor speed, torque and efficiency…

Problem Statement: Run MATLAB demo ‘Speed control of a DC motor using BJT H-bridge’. Modify the model such that armature current doesn’t shoot up when motor changes direction from forward to reverse.  Refer to help section of ‘The Four-Quadrant Chopper DC Drive (DC7) block’. Compare it…

Problem statement: 1.  Which types of power converter circuits are employed in electric and hybrid electric vehicle?    2. An Electric Vehicle's powertrain with 72V battery pack in shown in the diagram below. The duty ratio for acceleration operation is 'd1' and for the braking operation the duty…

 Problem Statement: What is the difference between mapped and dynamic model of engine, motor and generator? How can you change model type?  How does the model calculate miles per gallon? Which factors are considered to model fuel flow?  Run the HEV ReferenceApplication with WOT drive cycle. Change the grade…

Problem Statement: Use the ADVISOR tool and simulate the following  For EV_defaults_in file, if cargo mass is 500 kg with all other default conditions, can the vehicle travel for 45 km with FTP drive cycle? Conclude your observations. In the above case, try changing the battery capacity and repeat the simulation.…

Problem Statement: Write a function that extracts the 14 co-efficients and calculates the enthalpy, entropy, and specific heats for all the species in the data file. You will be reading this file NASA thermodynamic data(Tip: use fopen and fgetl). The formulae are shown below. Here R is the universal gas…

Problem Statement: Write a code in MATLAB to optimize the stalagmite function and find the global maxima of the function. Clearly explain the concept of genetic algorithm in your own words and also explain the syntax for ga in MATLAB in your report. Make sure that your code gives the same output, even…

Problem Statement: Write a program in Matlab\Octave that will simulate the pendulum motion with the following parameters: L=1 metre, m=1 kg, b=0.05. g=9.81 m/s2. Simulate the motion between 0-20 sec, for angular displacement=0,angular velocity=3 rad/sec at time t=0. Theory: The above given equation represents the second…

Aim: To write code that can solve an otto cycle and make plot for it.  Code creates a PV diagram  Code outputs the thermal efficiency of the engine. Theory: The Otto Cycle is used to characterize the operation of the Spark Ignition Internal Combustion Engine. It was proposed by Nicholas Otto in 1876.…