Week - 4 - 2D meshing for Plastic components

Aim: Development of a Door Trim panel   Intent:  To create thickened plastic components using the class A surface of the following door trim panel.   Objective: To create a thickened component with nominal thickness using class A. To create B surface features using the master section reference  …

PFA zipped files.

Aim: Create the Door Trim Lower 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 Body of content: From the Given Class A surface, B Surface…

Aim: To Create a Pillar design with the help of the master section Body of content: From the Given Class A surface, B Surface has been created by offset command By doing this there were many missing elements in the CLASS B surface  Sorted out each and every missing element in the Class B Surface with help of various commands…

Aim: To Create the Dog House for the Door Trim considering the design rules Body of content: From the Given Class A surface, B Surface has been created by offset command By doing this there were many missing elements in the CLASS B surface  Sorted out each and every missing element in the Class B Surface with help of various…

Aim: To Create the rib and screw boss for the Drill Handle considering the design rules Body of content: From the given class a Surface creates a closed surface and creates a body Create a sketch for the ribs and the screw boss on the surface Pad the sketches and assemble them to the main body Draft the sides and fillet…

Aim: To Create the Core and cavity blocks for the switch bezel. Body of content: from the previous switch bezel project, the inputs are taken. Creating the tooling axis, Now we have to see which surface will create problems or will be difficult to be tooled and make a line along that surface using point to point option.…

Aim: To Create the Bumper 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.    Body Of Content:   As Class A surface which is given in CATPART…

AIM : To perform draft analysis for the given class A surface and make a surface model then close the volume with the body and again check the draft analysis. PROCEDURE : DRAFT ANALYSIS : No parts can be ejected from the tool if it is having a straight 90 degree profile from its base surface. A small draft angle is provided…

Aim: To come up with a back door design, use appropriate design methodologies, and provide the necessary reinforcements and embosses.  Solution: DESIGN OF BACKDOOR In the crowded automotive market, there are some basic types of vehicles. They are SEDAN COUPE SPORTS CAR STATION WAGON HATCHBACK CONVERTIBLE SPORT-UTILITY…

Aim: For the Given Roof styling, create an ASSEMBLY by developing the essential flanges for the outer roof and creating the reinforcements.   Solution:  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…

Aim: To calculate and optimize the section modulus for the designed car hood.   Solution: Section modulus: Section modulus is a geometric property for a given cross-section used in the design of beams or flexural members. It is termed as the ratio of the second moment of area and distance from N.A. (Neutral axis) to the…

Aim:  Follow the given Master section to create the Drip Area   Solution: DESIGN OF FENDER A fender is the part of an automobile, motorcycle, or other vehicle body that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other road…

Aim: To calculate the Wheel Arch gap at required points and check whether the car passes the European standard.   Solution:  Fender: A fender is a part of an automobile, motorcycle, or other vehicle body that frames a wheel well. Its primary purpose is to prevent sand, mud, rocks, and other road sprays from being thrown…

Aim: To design Hood Outer Panel, Inner Panel, and the necessary reinforcements by following the Master Section.   Solution: Create the 'offset curve in face' for a distance of 20 mm as shown in the picture. Use fillet sharp corners to ensure that sharp corners are replaced by the best-fit fillets (30 mm). Trim the working…

Write one page about Underbody coating and its purposes. its types in detail, and its pros and cons.   Underbody coating is usually a dense cladding (often based on rubber) applied uniformly to the undercarriage of the automobile. It is normally sprayed or painted on when the car is just out of the dealership and is clean. The…

Case:  Mr D.S. Pughazhyendhii is a married man who lives in Bangalore which is a highly crowded city. His Family comprises five members including his wife, a five-year-old boy, his father, and his mother. He visits his native place Madurai which is 500kms away from Bangalore once a month. Also, he will be using his car…

Aim: To model the Radar mast and assemble the Yacht using SolidWorks.   Solution:  1. Radar Mast: Front View: Top View: Left View: Isometric View:   2. Yacht Assembly: YACHT- A yacht is a watercraft used for pleasure or sports. The term originates from the Dutch word "jacht" (which means “hunt”,…

Aim: To write the Report on the Assembly of the Chopper Model.  Solution:  AMERICAN CHOPPER'S RENDER- Photoview 360 rendering is a SolidWorks add-in that helps us in rendering our solid models.   Steps which are involved in renderings are- First comes scene setup so set up your model in the desired…

Aim: To perform the simulation according to the given parameters and get the desired output requests.   Procedure:  PRE-PROCESSING :  Make sure the unit system is in Kg mm ms by checking the starter file. Create a type 7 interface on the whole vehicle body as follows. Go to tools-->penetration check-->select…

Aim: To perform the crash analysis according to the given conditions and obtain the desired output requests.   Procedure: PRE-PROCESSOR (Radioss) :  Import the model and check the unit system in the starter file. Create a type-7 interface for the whole vehicle body by selecting all nodes and elems for slave master respectively.…

Aim: To mesh the given bumper assembly according to the required criteria. To perform the given simulations according to the conditions required and notice the change in results.     Procedure:  Import the model bumper into the hypermesh pre-processor. Using geometry cleanup fix any duplicate surfaces that may be present…

Aim: To perform a comparative study on rupture plates by assigning different material properties to the same component and noticing the difference in fracture mechanics. Procedure: The results are discussed based on the 5 parameters given in the question above :  1. The Total number of cycles, Energy error, mass error…

Aim: To compare the results with base simulation and improve shell element properties.   Case 1: Setup and Procedure of Base Simulation Import the engine file into the Radioss block 120 Change the Run time from 60ms to 55ms 3. Changing the animation steps to 50 so the Tfreq value changes to 1.1ms. 4. Select…

Answers to Questions: (1). Check the material properties of the rail component and calculate the speed of sound in steel rail=_______ Solution 1:  Given: We know that -- Calculation -- Speed of Sound = `((Modulus)/(Density))^½`                      [Under root can be represented as ^½ ] Speed of Sound = `(210000/0.0078)^½` …

Aim:  To carry out the geometry cleanup operation on the given 3 files. Practice  Clip Repair Mounting Bracket There should not be any free edges, convert all of them into refined geometry. To clean the geometry, Extract and clean the midsurface, create a 2D mesh with a target length of 5mm, min 3.5mm max 7mm, and assign…

Aim: For the given assembly, check for the geometrical errors and mesh with the given element Quality criteria. Assign thickness for the midsurfaces after meshing the component. Use Appropriate connections to connect the component as suggested and perform the Symmetry command to reflect the half-finished model to…

Aim:  1. For the given component, check for the geometrical errors and mesh with the given element's Quality criteria. 2. Assign the thickness after meshing the component. 3. Prepare a detailed report on the approach for the challenge.      The quality criterion to be followed: Abstract: In this project, the instrument…

Aim: To practice all the Morphing techniques. Perform morphing for the Model and Increase the Height of the Dog houses and Ribs   Morphing: Morphing is the Design change terminology. It is used to change the design of any component without any Numerical Inputs. It is used to adjust the shape and size of the component to…

Aim: For the given Rear door FE model, create and apply different PIDs for different components and perform suitable connections.   Types of Connections: 1. Bolt connection Bolt connections are formed from two or more holes, which are either shell or solidly meshed. Mostly, bolt connectors consist of a head, washer, body,…

The tool test was completed successfully.

Aim: For the given Rear view mirror component, check for the geometrical errors and mesh the Surfaces with the given 2D element Quality criteria as given below. Procedure: 1. Import the geometry and check for any geometry errors. If any geometrical errors are present, fix the errors by using the auto-fix option. 2. Mesh…

The tool test for both models was completed successfully as per the given requirement.

Aim:  For the given Plastic Bottle Cap model, check for the geometrical errors, take the mid surface by suitable mid surfacing techniques and mesh the same with the given element Quality criteria.   Procedure: 1) Import the model from File>Open>select the CAD File>open. Then the cad file will be opened in the ANSA. 2)…

  Aim: For the given Hood model, take the mid surface for all the components after checking the geometrical errors and mesh the mid surface with the given element Quality criteria using ANSA software.   Solution: 1) Import the .stp file in ANSA software by navigating to File>open>select all format>select the model from…

Aim: To build a 2D mesh for the floor panel of the car with the given quality criteria and after meshing assign the thickness to the mesh as mentioned.    Solution: The given component is a rear wheel holder of the car. First import the (.hm) file of the wheel holder of the car. Then we take the mid surface of the model…

Aim: To create a 2D mesh on the side door plastic component according to the quality criteria and apply the thickness to the mesh.   Solution: The given component is a plastic component which is a side door model. These types of plastic components have varying thicknesses and are having a large number…

Aim: To create connectors for various parts of the given model as per the given quality parameters.   Solution: Steps: First, download & import the model in Hypermesh. Then update the criteria file settings & 2D mesh the model. Next check for mesh quality, correct any errors, and create the connections…

Aim: To create 3D meshes for the models provided in the challenge according to the parameters mentioned.   Solution 1:   TetraMesh Generation Method: 2D to 3D Conversion Elements sizes: Min- 2 Units, Target- 5 Units, Max- 7 Units  Tet collapse: 0.15 Procedure: Import  the housing files by using import geometry. Remove…

AIM: mesh the following components individually and follow the quality criteria of mesh as per the given data. OBJECTIVE: To import the following geometry file and check for solid surfaces and geometrical errors. To extract the midsurface of each component individually and check for geometrical errors. To mesh the individual…

 Aim:  Mesh the Given component with the Size of 5 Units. Create 1D elements on the following component with the given cross-section and DOF a. Rod element:- Translational DOF should be Constrained with RBE2 link Cross-Section: BOX- Dimension a= 12 mm                               dimension b=10 mm                    …

Aim: To prepare a Battery pack of capacity 18 kWh with an ANR26650M1-B cell.   Solution:       Battery Pack Drawing of Configuration of 47S47P:     General steps followed to design a battery pack: 1 - Design of cell holder (Bottom and Top) The main function of a battery holder is to keep cells fixed in place safely and…

Aim:  1. To simulate the 3 test cases from the harness dashboard and write a detailed report on the results 2. What is coulomb counting? Refer to the above model and explain how BMS implements coulomb counting for SOC estimation?    Solution 1:   Test Case 1: From the plot, it is seen that the vehicle…

Aim:  1. To prepare a table that includes materials & chemical reactions occurring at the anode and cathode of LCO, LMO, NCA, NMC, LFP, and LTO types of lithium-ion cells and give a detailed explanation of it. 2. To compare the differences between each type of Li-ion battery based on their characteristics.   Solution: …

Aim: To design and model an electric rickshaw using Matlab and Simulink Objectives: To create a detailed MATLAB model of an electric rickshaw (three-wheel passenger vehicle) as per the details below: 1. Rear wheels driven by PM brushed type motor2. Assume efficiency points of motor controller and motor3.…

Aim: To create a MATLAB model of an electric car that uses a battery and a DC motor, choose suitable blocks from the Powertrain block set and prepare a report about the model including the following   1. System-level configurations   2. Model parameters   3. Results   4. Conclusion Theory:…

Part A: 1. To search and list out the total weight of various types of aircraft.  2. To list out the difference between ground speed and airspeed? 3. Why is it not recommended to use aircraft engine power to move it on the ground at the Airport?  4. How an aircraft is pushed to the runway when it is ready to…

Aim: To calculate the energy required for braking for a defined driving cycle. To understand the analogy of the development of braking torque of electric motors at high speed similar to starting and the coordination of electric and mechanical brakes?  To develop a MATLAB program that plots the contour of given motor speed,…

Aim: 1. To explain a MATLAB demo model named ‘Speed control of a DC motor using BJT H-bridge’, comment on the armature current shoot-up from the scope results and compare it with the H-bridge model. 2. To develop a 2-quadrant chopper using Simulink & explain the working of the same with the relevant…

Aim:  1. To study the types of power converter circuits that are employed in an electric and hybrid electric vehicle?    2. To calculate the EV steady-state speed if the duty cycle is 70% from the vehicle speed-torque characteristics  equation            …

Aim:  To study the difference between the mapped and dynamic models of engine, motor, and generator and check if the model type can be changed. To study the calculation of miles per gallon by the model and the factors that are considered to model fuel flow. To run the HEV ReferenceApplication with WOT drive cycle…

Aim: To use the ADVISOR tool and simulate the following: 1. To calculate if the vehicle can travel for 45 km with an FTP drive cycle for the EV_defaults_in file when the cargo mass is 500 kg with all other default conditions. 2. To change the battery capacity and repeat the simulation in the above case. 3. To perform a…

Aim: To carry out a system-level simulation of an all-terrain vehicle using Simulink.   Objective: To prepare a technical report on BAJA ATV explaining model properties and comment on the results.    Theory: An all-terrain vehicle (ATV) refers to a motorized single-seated tri or quadricycle bike and buggy that is designed…

Aim: To implement the control logic of the Washing machine and Gear shift mechanism using Stateflow.   Objective:  1. To implement control logic of a washing machine using Stateflow as per given sequence:  - If the power supply is available, the system gets activated  - If the water supply is not available, stop the process…

Aim: To simulate a doorbell and heater using Simulink   Objectives:  1. To observe the physical movement of the plunger when the switch is closed for 2 seconds and then released.  2. To use a thermistor to sense the temperature of a heater and turn on or turn off the fan as per below conditions:…

1.AIM: To write a function that extracts the 14 temperature co-efficients and calculates properties like molecular weight, enthalpy, entropy, and specific heats for all the species in the given data file. To plot and save enthalpy, entropy, and specific heats for the local temperature range specific for each species…

1.AIM: To write a program on Matlab to optimise the stalagmite function and find the global maxima of the function. To explain the concept of Genetic Algorithm and the syntax for ga.   2.INTRODUCTION: A Genetic Algorithm (GA) is a search-based optimization technique based on the principles of Genetics and…

1.AIM: To write a program in Matlab to simulate the pendulum motion.   2.GOVERNING EQUATIONS:  The Ordinary Differential Equation (ODE) represents the equation of motion of a simple pendulum with damping as follows:   3.OBJECTIVES OF THE PROJECT: To write a program in Matlab to simulate the pendulum…