Week 7:- Base Unit Design Challenges 1

  AIM: To define the connectors as electrical using an Electrical part design workbench and to define all its properties. The sequence of operation: Create required Geometrical parameters: For C-DT06-08SA  For C-2-174357-2 For C-0085229-01-3 Define Part as Connector: For C-DT06-08SA …

AIM: Create a BOM and Hardware list (BOP) for the complete Fixture assembly   Bill of Materials (BOM): A bill of materials (also known as a BOM or bill of material) is a comprehensive list of parts, items, assemblies and other materials required to create a product, as well as instructions required for gathering and using…

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 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   INTRODUCTION  The fixture design…

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  INTRODUCTION  The fixture design after the 3D finishing process has to be done with 2D finishing before it is sent for manufacturing. All the dimensions…

1.What are the drawing templates? A) Drawing Templates: If compared with the verbal or written description, drawing offers a far better idea about the shape, size & appearance of any object or simulation or location, that too in quite less time. Hence it has become the best media of communication not only in engineering…

AIM: Perform 3D finish for all units of Assembly design. Create Rough locators for Assembly. 3D-FINISHING: 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 ensures the easy assembly of all…

1) What do you understand by the 3D finish process? A) 3D finish: 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 ensures the easy assembly of all the units. The hole concentricity and…

AIM: To Design a base unit for the Pin units, Clamp units, Swivel clamp units with all weldments for the given Car panel. SOFTWARE USED: CATIA-V5  INTRODUCTION: Base Unit: A base unit is designed to mount all other units(Clamp unit, pin unit, rest unit, etc) of the tool, also other parts necessary for a tool like…

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…

OBJECTIVE: To design 3 different types of Swivel clamp units with different risers, blades, and clamp arms for the given panel & to design a pin clamp unit for the given car panel. ABSTRACT: In this project, I have designed different types of swivel clamp unit by validating a swivel clamp cylinder and by considering…

OBJECTIVE: To design 3 different types of power clamp units with different riser, blade, and clamp arm & to design 2 different types of rest unit for the given car panel. ABSTRACT: In this project, I have designed different types of power clamp units by validating a power clamp cylinder and by considering a clamping…

AIM:- To design 2 different types of fixed pin units with different pins, riser, blade & block, and 2 different types of retractable pin units with different pins, riser, blade, cylinder & block. To fix the pin retainer & the shim block using standard screws we need to find the length of the screw using the above-mentioned…

OBJECTIVES: Frontal crash-BIW Checking the unit system and either following [Mg mm s] or [Kg mm ms]. Creating appropriate interface, friction 0.2 and recommended parameters. There should be no penetrations and intersections. Creating a rigid wall with friction 0.1. Adding masses to reach target weight 700kg while getting…

Q1 Ans Design methodology So in this methodology, we learn about three design processes, we're going to study how do we proceed while doing a design. And one of the things that we take care of structuring or design tree so we'll be learning how to structure the design tree, and how to name the particular component…

Q1 Ans PROCESS OF PROJECT EXECUTION ACTIVITY: The above figure shows the process involved in process execution activities. It is a general activity that is involved in BIW fixture & Tooling. It is the starting phase of every project. It starts with the basic requirements/RFQ we received from the customer. As shown…

Q1 Ans BIW - Body In White BIW refers to the welded sheet metal components which form the structure of the vehicle to which the other components (like engine, chassis, exterior & interior trims) will be married or assembled. The stage in automotive design or automobile manufacturing in which the car body sheet metal…

Objective :-  Neon side crash -BIW Check unit system and either follow [Mg mm s] or [Kg mm ms]. Create appropriate interface ,friction 0.2 and recommended parameters. Make sure of no penetration and intersections. Create rigid wall with friction 0.1 as per referance model. Compare the model weight with the referance model…

Objective :- Run the model as it is. Name it Law2_epsmax_failure. In/FAIL/JOHNSON, change Ifail sh=1, Dadv-1 and Ixtem=1. Run the model as Law2_epsmax_crack. Delete/Fail/JOHNSON card. Run the model as Law2_epsmax_nofail. Delete the value of EPS_p_max and run the model with name Law2. Convert this material model to Lawl…

Objective :-  Comparison of results with base simulation and improved shell element properties 1. Using the crash beam file from the previous assignment, change the run time to 55 ms. In this objective we have to import crash beam file (_0000.rad) by using 'import solver desk' option Then change run time to 55 sec.…

  Questions: 1. Check the material properties of the rail component and calculate the speed of sound in steel rail=_______ 2. The length of the rail is about 1000 mm.calculate the time takes for a shock wave to travel from one end of the rail to the other. 3. Time for sound to travel length of rail=______…

Objective : 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 refine geometry. Clean the geometry. Extract midsurface. Clean midsurface geometry. Ignore holes less than dia 5mm. Create 2D mesh…

 Objective :- Mesh the model of inner door panel with given quality criteria. Target Element Length = 4 Units S.N Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3 Warping 15 4 Taper      0.5 5 Min. Length 2 Units 6 Max. Length 6 Units 7 Min angle Quad 45 8 Max angle Quad 135…

Objective :- Meshing of Rear Wheel Holder with mentioned quality criteria and assign thickness. Target Element Length = 5 Units S.N Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3 Warping 15 4 Taper      0.5 5 Min. Length 2 Units 6 Max. Length 8 Units 7 Min angle Quad 45 8…

Objective : Creation of different types of 1D connector to join two or more components.   Given model is already having the mid surface of the component. It is directly meshed using 'automesh option with element size of 5mm with mixed element type  All the connectors were applied one by one as follows: 1)  Seam-Quad(angled+capped+L)…

 Objective :- Create tetramesh for given componenets using different options in hypermesh(2D to 3D conversion, quick tetra mesh and volume tetra mesh) with quality criteria. 1) 2D to 3D conversion method   Create a Teramesh for Housing component with the following quality criteria. TetraMesh Generation Method: 2D…

Objective : Mesh the hood components with given quality critera.   Procedure :  Import Geometry :- First of all import Hood model using import tool. we have four different components (Inner panel , outer panel, hinge reinforcement, latch reinforcement).         Then we have to clean…

Objective : Mesh the Given component with the Size of 5 Units. Create 1D elements on the component with given cross-section and DOF.   Given comonent :     Procedure for meshing to given component    1) Midsurface creation and extraction First we have to import model in hyperworks and go to…

Aim : Drtail analysis of simulation of an all-terrain vehicle.    Objective :    Continuous Variable Transmission (CVT)                                       A continuously variable transmission (CVT)…

Aim : Implement control logic of a “washing machine” using Stateflow.   Objective :  If the power supply is available, the system gets activated  If the Water supply is not available, stop the process & indicate through LED Soaking time should be 200s followed by Washing time of 100s.…

Aim: Make a Simulink model of Doorbell using solenoid block  Objective:  When the switch is closed the electromagnet receives electrical power from the battery and pulls the metal arm to hit the bell producing sound.  Create a situation where the switch is closed for 2 seconds and then released.…

DESIGN OF BACK DOOR    BACK DOOR:                                                       The back door of a car is the vehicle's main storage or cargo compartment,…

Objectives   Create a car roof model based on the styling surface master sections given for various parts with mastic points & rein forcements.  Determine whether the design is complying with heat distortion criteria through curvature study on the roof.  Check section modulus of front roof rail,…

Section modulus For general design, the elastic section modulus is used, applying up to the yield point for most metals and other common materials. The elastic section modulus is defined as S = I / y, where I is the second moment of area (or area moment of inertia) and y is the distance from the neutral axis to any given…

FENDER:                Fender is the american english term for the part of an automobile, motorcycle or other vehicle body that frames a wheel well.Early automobile fenders set over the wheels to prevent mud, sand and dust being thrown on to the body and the occupants. Fenders…

Aim:         Design Hood outer panel, inner panel and the necessary reinforcements by following the Master section mentioned with the design parameters. Given Inputs:                     HOOD:            …

UNDERBODY COATING      As considering factor like climate,  every vehicle needs proper care and protection. Undercoating helps protect your vehicle against rust and corrosion.Seals on the underbelly parts have gotten a lot tighter and more effective at keeping out dust and moisture, but there are other factors to consider.…

  BENCHMARKING Benchmarking in automobile industry involved structured comparisons between similar product, services or processes of some dimensions of performance. Performance Driveability Advanced Driver Assistance Systems (ADAS) Sound / NVH RDE: CO2 / Real life fuel consumption Pollutant emissions Friction Thermal,…

PROJECT REPORTON DESIGN AND DEVLOPMENT OF CAR INTERIOR DOOR TRIM 1⦁ INTRODUCTIONInterior trims: As we know there are many parts in the car. In a car trims are all aesthetic parts that do not add functionality to the vehicle which enhancing the aesthetic and cool factor. They are dividing into two parts •Interior trims:…

TOOLING AXIS       1) First extracted circle and created point over it. took two planes in X and Y direction and intersected in X direction first then created lines over inclined and by bisecteing method created tooling axis in X direction       2) Then similarly in Y direction intersected…

DESIGN OF APPLIQUE  TOOLING AXIS       1) We had flat class A surface so directly created point over surface and drew line in Y direction as tooling axis 4 WAY LOCATORS       1) first thicked class A surface. drew positioned sketch of 4 way locator and paded it. gave draft angle…

REPORT ON B PILLAR        We had class A surface and master sections. first checked continuty of surfaces if some patches or unimproved surfaces found then improve it.    TOOLING AXIS       1) With the help of master sections extracted four lines of master sections.…

SCREW BOSS DESIGN       1) Drew positioned sketch of screw boss and paded it in part workbench and drafted it with 0.5degree.               2) Drew sketch of ribs and paded it and drafted it with 0.5 degree. then union trimed with screw boss and assembeled in main body.             3) Deactivated screw bosses for while…

RIB DESIGN        1) For Rib design followed following steps.                               2) Calculation of different parameters like            a) rib thickness at tip = >0.75 =0.786…

TOOLING AXIS       1) Extracted base surface and created point on it. created inclined lines and by bisecting method created bisecting line.         2) Drew line in YZ direction and gave constrained to it. further by bisecting line method got tooling axis.     DRAFT ANALYSIS…

TOOLING AXIS       1) Extracted base surface created point on it. intersected with YZ direction. walls was 90 degree hence took line in Z direction as tooling axis. B SURFACE       1) Extracted all side walls utrimed and extrapolated it. then trimed all unwantd parts and…

1) TOOLING AXIS       1) First of all checked continuity by boundry command. There was no gap between two surfaces       2) Extracted the base surface and created point on center. then drew sketch of lines in yz direction and by bisecting line command got dummy tooling axis in y direction. similarly drew sketch in x direction…

TOOLING AXIS       1) To find tooling axis first of all checked whether there is no gap between two surfaces.       2) Checked all possible directions to getting tooling axis. checked all  X,Y,Z direction and checked in which direction covers all surfaces.       …

DRAFT ANALYSIS       It is command which enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying the zones on the analyzed element where the deviation from the draft direction at any point cooresponds to specified values.…