Week 7- Base Unit Design Challenges 2

Steps followed: The indivisual parts are first created in a part design workbench. All the parts are designed using projection point. All the sketches are ensured to be iso-constrainted. The parts are then assembled in the assembly work bench. The parts are assembled using constraints such as conicidance, surface to surface,etc.…

Design of B-Pillar  Objective: To create class B and Class C surface from the given class A Create tooling axis for the part Perform draft analysis on the part Create the engineering features as per the master section Create a solid part body with the engineering features Class A surface: Master section: Creating tooling…

Design of Door Applique Objective: To design door applique CLASS A, B and C surface Making a solid part from the surface Adding locators to arrest the movment of the door applique Adding heat stakes to attach the door to base panel Creating tooling axis: The main tooling axis made on a point on perpendicular to a plane.…

Design of Screw boss and Dog House Objective: To create screw house and dog house as per the design procedure Images and tree structure for Screw Boss and Dog House: The dog house has Secondry tooling axis to clear it, as it needs a side core to be created : The dog house had draft of 1.5 degree draft for both the tooling…

Design of Rib Objective: To design a rib on the coin holder according to the design rules Draft analysis: The side walls are 90 degree to the base. The tooling axis will be 90 degree to the base. Design of ribs: the ribs are designed as per the given design rules: Expanded feature tree: Ribs: Root circle: diameter: 2.7mm…

Design of Core and Cavity block for Switch Bezel Objective: Make Core and Cavity for the Switch bezel Mark the Parting line and parting surface Switch Bezel: Creation of the tooling axis: A surface is extracted from the base of the cavity and a point is created at the center of the surface. A axis system is created on…

Design of Class B and C surfaces and creating solid part Objective: Create class B and Class C surface. Creating tooling axis and performing draft analysis. Creating solid part out of the final closed surface. The final solid part must have a thickness of 2.5mm. Given class A surface: Draft analysis of the class A surface…

Design of arm rest using and performing draft analysis Objective: Design class B and Class C surface from the given Class A surface Perform draft analysis on the Class A surface and the final solid part Make a solid part from the complete closed surface with thickness on 2.5mm. Given class A surface: Performing draft analysis…

Design of a Switch Bezel Objective: To design a Class B and Class C surface To create a solid part from the final surface To perform draft analysis on the class A surface and the solid part Class A surface: Draft analysis: To perform draft analysis tooling axis is created. Steps to create tooling axis: Making tooling axis…

Design of a Base bracket and draft analysis Objective: Design a base bracket from the given class A surface Performing draft analysis of the class A surface  Making Class B and Class C surface Performing draft analysis on the final solid part Draft Analysis of the Class A surface: 1. Make a Dummy/Temporary tooling…

Draft analysis of a fan cover Objective: To perform draft analysis on the Class A surface of a fan cover Class - A surface: Draft analysis steps: Creating tooling axis: 1. The first step is to Perform join operation and make the given surface in one surface: 2. Make sure there are no open boundries in the surface 3. Create…

Making Bill of Material and Bill of Part for fixture unit Objective: Making Bill of Material for fixture unit in challenge 8 Making Bill of Part for fixture unit in challenge 8 Bill of Material: This is a sheet which contains the information about assembly part, sub-assembly parts, raw material for the manufacture, repair…

Designing keysheets for clamp and pin unit objective: Design key sheet for all the clamp unit in challenge 8 Design key sheet fo all the pin unit in challenge 8 Pin unit: P001_Z01_ST01_01_00_FIX_PIN_UNIT: Assembly: PIN: RETAINER: L-BLOCK: SHIM: SHIM-2: P001_Z01_ST01_02_00_CLAMP_UNIT: ASSEMBLY PIN: RISER: BLADE: SHIM: P001_Z01_ST01_03_00_CLAMP_UNIT:…

Design of the key sheet  Objective: Make a key sheet for the entire fixture Make key sheet for the indiviual parts of the base unit and the pin unit Key sheet for the entire fixture assembly: Isometric view for the fixture: Key sheet for the base unit: Key sheet for the base plate: This key sheet contains all the…

1. What are drawing templets ? Drawing templets are the blue print which are useful in making the design and are used for manufacturing the product. This are the templets according to the customer specification. This are the blueprints used for designing the different unit There are many templets that are available on…

Design of rough locator for car panel and 3D finish of the fixture Objective: Design rough locators for the given car panel and the already made design of the fixture unit Perform 3D finish for the complete fixture unit What is 3D finishing 3Dfinishing is the final process in which the fixture is made ready for testing…

1. What do you understand by 3D finishing process ? The 3D process is the fianl stage when the design is completed and is needed to be freezed. The design is then given for the manufacturing process. Simulation is done on the finished design to check for flaws and feasability 2. What are the points need to be taken care…

Design of base unit Objective: The objective is to design the base unit for the given car panel and all the other BIW fixtures from previous challenge The car panel should be constrained by the 3-2-1 principle What is a base unit: The base unit is the part which holds up all the other fixture and parts. It also consists…

1. What is the base unit ? What are the typical parts of the base unit ? A base unit is a unit on which other units will be placed. Units such as the Pin, clamp, siwel, etc. are placed on the base unit. The base unit also consists of the valve box. This box houses the pneumatic valves that are needed to operate the clamps…

Design of Siwel clamp unit and a pin clamp unit Objective: The objective of this challenge is to design 3 different swiel clamp unit and a pin clamp unit.  Design methodology for swiel clamp unit: The clamp arm is designed first and then the clamp holder is designed. The clamp holder and the clamp arm is then positioned…

Design of Clamp units and Rest unit using CATIA V5 OBJECTIVE: Design two different rest units  Design three different power clamp units INTRODUCTION: The clamp unit is a fixture used for holding the car panel in place. The clamp unit is operated by a pneumatic cylinder. The cylinder opens and closes the clamp of the…

DESIGN OF PIN UNIT USING CATIA V5 Objective: Design two types of fix pin unit Design two retractable pin unit Software used: CATIA V5 Fix pin unit:  The fix pin unit is used to hold the car part in a specific position in order to store the part or perform machining operations on the car part. Retractable Pin Unit:…

1. what is design methodology ? The design meethodology contains: purchase order- In this the customer places the order to start the project. Input from the customer- Functional requirment- Prefered standard component Car product Layout Ergo data Weld study Standard detaling templet percentage completion criteria The percentage…

1. What is the process of project execution activity ? The project execution activity is the step by step procedure to design and manufacture a fixture. RFQ received- Request For Quotation. Here the customers requirments/specification are received.  1st Specification discussion meeting- The disscusion is…

1. What is BIW & define its parts ? The Body In White is a manufacturing stage at which the cars body is joined/welded together. This excludes moving parts (doors, hood, rear door,etc), trims (glass, seat,etc) and any other chassis sub-assemblies. The BIW can be a monocoque design, where all the members carry load…

Design of the back door of a car using NX CAD OBJECTIVE: To design the back door of the car To make an inner panel for the back door make all the necessary re-enforcements INTRODUCTION: The back door of a car is use to acess the boot of the car. The back door consists of two or three panels. The outer panels and the inner…

Design of Automobile Roof and it's components using NX CAD Introduction: The roof is part which starts from A-pillar and goes upto the D-pillar. The roofs purpose is to provide cover to the passenger in side the car and protect the passengers from elements like sun, rain, wind, etc. The roof also prevents unwanted objects…

Design of fender Objective: Design Drip area according to the master section Bumper mount Sill area A-Pillar Mount Baffle mounting Software used: NXCAD 12 Tools used: Law extension Extend sheet Datum sketch project curves Curve on surface bridge curve Thicken offset curve in face Dart sew face blend  edge blend…

Sectoin moduluds of the hood Section modulus: It is a geometric property used for design of beams. The section modulus gives the strength of the part. The section modulus is the ratio of the Moment of inertia of the part to the distance of the neutral axis from the outer most fiber. Section modulus=Moment on Inertia/Distance…

Desing and assembly of Hood using NX CAD Hood: The hood is also known as a bonet of the car. The main porpuse of the hood is to cover the engine, to style or give looks to the front of the car and to dissipatate the force during a head on colission. The hood is made up of two pannels the Outer Pannel and the Inner Pannel. Both…

Underbody Coating: The underbody is the part of the car which acts as the floor of the cabin. This part is exposed to the ground and the atmosphere. This part is exposed to dust, rocks, water and many other elements. Due to oxidation the underbody can erode and rust causing damage to the car, and making it dangerous to…

Benchmarking:Benchmarking is the process of comparing products or services with other products or services of same catogery. This helps the designers/manufactures/service providers to improve their products and services and reduce the time and cost for development of the product. It serves as a standard to judge the performance…

Design of Metal Bracket-II using NX 12 Objective: To Design the metal bracket as per the given diagram and dimensions Make the Flatpattern Make a 2D drawing Introduction: In this exercise a metal bracket is designed according to the given dimensions in the drawing. All the holes and flanges are made according to the given…

Design of brecket using NX CAD Objective: Make a bracket according to the given dimesions of the drawing Make a flatpattern Make a Drawing on the A4 sheet Introduction: A bracket is designed using NX CAD software Design methodology: Make a new sheetmetal part --> Select the datum plane --> Make a sketch according…

Design of odd shaped enclouser using NX CAD Objective: To make Odd shaped enclouser using NX CADm Make a Flatpattern Introduction: In this I learn to design Different types of shapes in nx cad as well as different types of angles Design methodology: Make a new part in NX CAD --> Goto application --> select modeling…

Design of Box assembly using NX 12 Objective: Create box assembly using NX 12 Software Create a flatpattern of the box assembly Make a Drawing on an A4 sheet Introduction: In this challenge a sheetmetal box is created in NX 12 software and a lid is created for the box. Various commands are used for the creation of the…

Design, Assembly and Rendering of a Tipper Truck using SolidWorks and SolidWorks Visualise Objective: Design the parts of the Tipper Truck Assemble the parts in solidworks assembly. Render a high quality image using photoview 360 and SolidWorks Visualise. Software Used: SolidWorks 2019-20 student Edition SolidWorks is…

 Design of casing using NXCAD 12 software Objective: To design a sheetmetal casing using NX 12. Draft the part drawing on an A4 size paper. Introduction: NX 12 is a sheetmetal design software used for making complex sheetmetal parts and then draft them on a paper. Design Methodology: Start the NX 12 --> Create…

Design, assembly and rendering of Sunseeker Predator Yacth using Solidworks Objective: Model the parts of a Sunseeker Predator Yatch using SolidWorks Assemble all the parts using solid works Give appropriate appearence to the parts in solidworks  Render images using photoview 360 Introduction: SolidWorks is a 3D modeling…

Design, Assembly and Rendering of American Chopper Bike using SolidWorks Objective: 1.The objective of this project is to design/model the parts of an American chopper bike in SolidWorks software 2. Assemble all the parts in SolidWorks assembly. 2. Render photorealistic images of the chopper using Photoview 360. 3. Render…