Week 3:- BiW Fixture Design Methodologies Challenges

 AIM To Develop a Door Trim panel from the given Class-A surface Input considering the OEM standards.  INPUT  SURFACE   The above image is the given input surface of the door trim panel, the input surface is subdivided into 4 parts and is worked in order to create a tooling axis, Class A surface, Class B surface, and Class…

MODEL 1 SKETCH OF THE SLIDER PATH SLIDER PATH MODEL ROTATING SUPPORT SKETCH ROTATING SUPPORT SKETCH FOR THE BASE OF THE SLIDER SLIDER BASE  SKETCH OF THE HOLES ON THE SLIDER BASE. SKETCH FOR THE PIN SLIDER WITH HOLES AND PIN. SKETCH OF SLIDER SUPPORT 1 SLIDER SUPPORT 1 SKETCH OF SQUARE BLOCK SLIDER SUPPORT 2 FINAL ASSEMBLY…

AIM To create the Class B, Class C from the given Class-A surface and add B side features to the component. Firstly, the connectivity of the given Class-A surface must be checked, and ensure that there are no gaps between the surfaces. It is clear from the above image that all the surfaces are continuous without any gaps…

 AIM To Create the Base Bracket Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.  Create the Heat Stakes and the locators considering…

AIM To Create the boss and Dog House for the Centre console coin holder considering the design rules. General Guidelines for Bosses:   Draft  - 0.5 degrees on walls of boss   Thickness -  Typically 40%* of the nominal wall at the base.   Height to Diameter Ratio -  3:1   Radii…

AIM To Create the rib for the Centre console coin holder considering the design rules. INTRODUCTION Ribs are indispensable functional structures on many plastic parts. It can effectively improve the rigidity and strength of plastic parts like the H beam. Ribs are generally designed on the non-appearing surface of the plastic…

 AIM  To create a Class B and Class C surface from the given class A surface of the Door Armrest and add thickness to it. To perform a draft analysis of the component.   Firstly, the connectivity of the given Class-A surface must be checked, and ensure that there are no gaps between the surfaces. t is clear…

AIM To Create the Core and cavity blocks for the switch bezel designed in the earlier challenge.  Creation of tooling axis for the given Class-A surface Tooling Axis direction is the direction in which the core and cavity open. The selection of tooling direction depends upon the product and the features of the product.…

 AIM To Create the Coin Holder Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.    Firstly, the connectivity of the given…

AIM  To Create the Switch Bezel Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.    Firstly, the connectivity of the given…

AIM  To Create the Base Bracket Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.  Creation of tooling axis for the given Base…

 AIM  To Create the tooling axis for the given Fan cover model meeting the requirements of the draft angle and perform the Draft analysis on the model. Creation of tooling axis for the given fan cover Firstly, the connectivity of the given Class-A surface must be checked, and ensure that there are no gaps between…

AIM  To Create a BOM and Hardware list (BOP) for the complete Fixture assembly from challenge 8. What Is a Bill of Materials (BOM)? A bill of materials (BOM) is an extensive list of components, and instructions required to construct, manufacture, or repair a product or service. A bill of materials…

1.What are the Drawing templates? Drawing templates are basically the drawing standards as per the customer’s specifications. Drawing templates are used for detailing different parts or units of the fixture. The drawing template will contain details like machining finish, tolerances, surface treatments, materials…

AIM To Create 2D Drawing for each Clamp Units with all child parts and also create Child pard drawing for the same for the Fixture assembly and to Create 2D Drawing for each Pin Units drawings with all child parts and also create Child pard drawing for the same for the Fixture assembly…

AIM To Draft a Key Sheet for the Complete Fixture assembly and Draft a Base Unit and the Fix Pin Unit drawings with all child parts for the complete Fixture assembly from challenge 8. INTRODUCTION  The fixture design after the 3D finishing process has to be done with 2D finishing before…

1.What do you understand by the 3D finish process? 3D Finishing is a process where the design is being completely and to be ready for final simulation and 2D detailing During the design finishing process, the nominality of the design is checked to have the easy assembly of the units. The hole concentricity and hole sizes…

AIM  To Perform 3D finish and create Rough locators for the Assembly Fixture design. INTRODUCTION 3D Finishing is a process where the design is being complete and to be ready for final simulation and 2D detailing. This is the stage in the process where the position of rough locators is identified.…

BASE UNIT DESIGN  AIM  To Design a Base Unit for the units designed for the BIW fixture with all weldments for the given Car 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…

1.What is the Base Unit? What are the typical parts of the Base Unit? 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. The parts of the base unit are as follows:…

SWIVEL CLAMP UNIT AND PIN-CLAMP UNIT DESIGN CHALLENGE   AIM To Design 3 Different types of Swivel Clamp Unit with Different Riser, Blade, and Clamp Arm for the given Car Panel and design a Pin-Clamp Unit for the given Car Panel. INTRODUCTION The swivel Clamp unit is a device that is used to hold the part tightly,…

CLAMP UNIT AND REST UNIT DESIGN CHALLENGE AIM To design 3 Different types of Power Clamp Unit with Different Riser, Blade, and Clamp Arm and design 2 Different types of Rest Unit for the given Car Panel. INTRODUCTION A Clamp is a device that is used to hold the part tightly, yet, firmly in the assembly, The clamp prevents…

PIN UNIT DESIGN CHALLENGE AIM To design the fixed pin unit and the retracting pin unit for locating a BIW panel in a Fixture. INTRODUCTION 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 is opposite to fixed unit which can be moved…

1.What is design Methodology? Design methodologies are the steps that are followed during the concept designing stage of the fixture. 1.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 delivered…

What is the process of project execution activity? Project activities are the various practices that are involved in the project from the beginning to the end of the project. The various steps of project activity are as follows. 1.RFQ  received It is the first stage of the project. RFQ stands for request for quotation.…

1.What is BIW & define its parts? In Automotive industries, BIW (body in white) is the common terminology used to describe the sheet metal welded structure. This structure is married with other components like engine, Transmission system and trims are joined. The name is derived based on the appearance of the structure…

BACKDOOR DESIGN USING NX CAD   OBJECTIVE  To design a car backdoor using the provided styling surface and appropriate design methodologies and provide the necessary reinforcements and embosses. INTRODUCTION A backdoor in an automobile is an essential part, which provides the opening and closing of the trunk in…

CAR ROOF DESIGN USING NX CAD   OBJECTIVE  To design a car roof using the Given Roof styling, Develop the essential flanges and reinforcements, Provide appropriate dimension and check for Draft analysis and do a curvature study using heat distortion criteria and snow load criteria formula. INTRODUCTION An automobile…

FENDER DESIGN USING NX CAD   OBJECTIVE  To  Design a front fender of a car from the given skin data and the master section and add various mountings such as Drip mounting, A-pillar, Sill, Bumper, C mounting, and Splash mountings.   INTRODUCTION The fender is part of an automobile that covers the wheel.…

SECTION MODULUS CALCULATION AND OPTIMISATION   OBJECTIVE  To use the Section from the Hood design and calculate the section modulus and optimize the design to improve the section modulus.   SECTION MODULUS Section modulus is significant in measuring the strength of a member due to its cross-sectional area.…

HOOD DESIGN USING NX CAD   OBJECTIVE  To Design the Hood outer panel, inner panel, and the necessary reinforcements by following the Master section.   INTRODUCTION A hood is an important component in automobile BIW design. A hood is also known as a bonnet, which is used to cover the engine compartment. The…

BENCHMARKING   Benchmarking is the comparison of the capabilities, features, and services of a company’s product with that of the products of the competitors. Benchmarking helps the company to analyze their product and identify what better they could do to stand out in the market.   BENCHMARKING CASE STUDY…

UNDERBODY COATING    INTRODUCTION A car’s underbody is exposed to the most wear and tear caused by muddy water, potholed roads, stones, and other obstacles on the road. Because it’s not in plain sight, we often do not see the damage. The Underbody Treatments offers you a long term solution for issues…

ADVANCED SHEET METAL DESIGN USING NXCAD – METAL BRACKET 2   OBJECTIVE To design a sheet metal bracket using NX sheet metal application.   INTRODUCTION Sheet metals are thin, flat pieces of metal that are formed by various industrial processes. Typical sheet-metal thicknesses are between 0.4 mm (1/64 in) and 6 mm(1/4 in).…

ADVANCED SHEET METAL DESIGN USING NXCAD – BRACKET   OBJECTIVE To design a sheet metal bracket using NX sheet metal application.   INTRODUCTION Sheet metals are thin, flat pieces of metal that are formed by various industrial processes. Typical sheet-metal thicknesses are between 0.4 mm (1/64 in) and 6 mm(1/4…

ADVANCED SHEET METAL DESIGN USING NXCAD – ODD SHAPED ENCLOSURE   OBJECTIVE To design an Odd shaped enclosure using NX sheet metal application.   INTRODUCTION Sheet metals are thin, flat pieces of metal that are formed by various industrial processes. Typical sheet-metal thicknesses are between 0.4 mm (1/64…

ADVANCED SHEET METAL DESIGN USING NXCAD – BOX ASSEMBLY OBJECTIVE To design a sheet metal Box Assembly using the NX sheet metal application.  INTRODUCTION Sheet metals are thin, flat pieces of metal that are formed by various industrial processes. Typical sheet-metal thicknesses are between 0.4 mm (1/64 in) and…

ADVANCED SHEET METAL DESIGN USING NXCAD – CASING DESIGN OBJECTIVE To design a sheet metal casing and creating a draft using the NX sheet metal application.   INTRODUCTION Sheet metals are thin, flat pieces of metal that are formed by various industrial processes. Typical sheet-metal thicknesses are between 0.4…

MODELLING AND RENDERING OF SUNSEEKER PREDATOR YACHT USING SOLIDWORKS   OBJECTIVE: The main objective of this project is to learn and familiarise with the user interface, sketch tools, surface tools, and various features of Solidworks. To make part models of various parts of Sunseeker predator yacht. To bring in the…

MODELLING AND PHOTOREALISTIC RENDERING OF AMERICAN CHOPPER USING SOLIDWORKS OBJECTIVE: The main objective of this project is to learn and familiarise with the user interface, sketch tools, surface tools, and various features of Solidworks. To make part models of various parts of an American chopper bike. To bring in the…