Week 8:- 3D Finishing Challenge 2

Aim: To assemble and apply GD&T to the butterfly valve assembly drawing.   Introduction: Butterfly Valve: A butterfly valve is a valve that isolates or regulates the flow of a fluid. The closing mechanism is a disk that rotates. A butterfly valve is from a family of valves called quarter-turn valves. In operation, the…

AIM: To design the backdoor for a car by using the provided styling surface and following appropriate design methodologies also, providing the necessary reinforcements and embosses.   Back Door Assembly Components: A backdoor is located at the rear of the car which provides access to the boot space to store…

AIM: To design a roof with all its components i.e. the front roof rail, bow roofs, center roof rail and rear roof rail by following the master sections and check for draft analysis also do the section inertia and curvature study.   ROOF: The roof or top is the portion of an automobile that sits above the passenger…

AIM: To calculate the section modulus using the section from Hood design and come up with a new section that has improved the section modulus of the previous section.   SECTION MODULAS: Section Modulus is the geometric property of the given cross-section of any shaft or beam structures It is the direct measure of the strength…

AIM: To design the Fender by creating the sill mount, bumper mount, A-pillar mount and drip area with the help of master section.   FENDER: Fender is the US English term for the part of an automobile (vehicle body) that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids,…

ABSTRACT: Welding is the most common process which is widely used when two metal parts are required to be joined together for some engineering application. In some cases, the strength of the welded joints is required to be calculated. The permissible stresses for welded joints in certain structures, such as unfired pressure…

AIM: To calculate the wheel arc area and decide whether the car will pass the European standards or not.   FENDER: Fender is the US English term for the part of an automobile (vehicle body) that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other…

AIM: To design the hood outer panel, inner panel and the necessary reinforcements by following the master section and create an assembly of hood inner panel, outer panel, latch, hinge and the reinforcements.   HOOD: The Hood or the Bonnet of a car is considered as the frontal enclosure component.The Hood is an opening…

UNDERBODY COATING: 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 and because it’s not in plain sight, we often do not see the damage. In Indian road conditions, a cars underbody is most prone to corrosion. Underbody coating…

BENCHMARKING: Benchmarking is the process of comparing your own organization, its operations or processes against other organizations in your industry or in the broader marketplace. Benchmarking can be applied against any product, process, function or approach in business. Common focal points for benchmarking initiatives…

AIM: To develop a Door Trim Panel from the given class A and master sections and also create the attachment features.   OBJECTIVE: To create the class B & C surfaces from the given class A surface for all components of the door trim To form a solid body i.e. thickened part for all components  Refer the master…

DESIGN OF SUPRA SAEINDIA STUDENT FORMULA CHASSIS SUBMITTED BY - MANAS PATIL PROJECT MENTOR - CHIKKAM SRIKANTH   Abstract: SUPRA SAEINDIA is an annual national level competition organized by the Society of Automotive Engineers India. From all over India, the selected Under Graduate & Post Graduate Engineering Student…

AIM: To create the individual parts from the 2D drawing provided and then create a complete assembly of those part files in the assembly workbench.   REPORT:  Download the 2D drawings for the components from the links provided Create seperate part files for each component Sketch the profile for the models and…

AIM: To develop the solid plastic component from the given master sections along with the engineering features and also perform the draft analysis.   REPORT: Examine the given inputs i.e. the master sections and the class A surface to develop the component  To create the tooling axis extract the opposite faces…

REPORT: To create the tooling axis extract the base surface of Door Applique class A, create a point in centre and create a line normal to the surface and from the point and we would get the Tooling Axis To generate the Class B surface extract the Class A Surface faces individually untrim them - extrapolate and…

REPORT:  General guidelines that need to be followed while designing the 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 - 0.25mm maximum radii.                 …

REPORT: Design rules to be followed for creation of Ribs                                                                           …

AIM: To Design the Door Arm Rest Plastic Component and adding thickness to it. REPORT: For the given Door Arm Rest catpart i.e. the class A surface first we need to make the basic checks i.e. check the continuity of the part ensure that there is no gap between the surfaces for this we can take the help of surface command…

AIM: To create the Core and cavity blocks for the switch bezel plastic component.   REPORT: For the given Switch Bezel catpart first we need to make the basic checks i.e. check the continuity of the part ensure that there is no gap between the surfaces we can take the help of surface command for this To obtain the Tooling…

 REPORT: For the given Coin Holder catpart first we need to make the basic checks i.e. check the continuity of the part ensure that there is no gap between the surfaces we can take the help of surface command for this To create the tooling axis create a axis system and form a intersect of Coin Holder Class A…

AIM: To create the Switch Bezel plastic component through the given Class-A surface   REPORT: For the given Switch Bezel catpart first we need to make the basic checks i.e. check the continuity of the part ensure that there is no gap between the surfaces we can take the help of surface command for this To obtain…

REPORT: For the given Base Bracket catpart first we need to make the basic checks i.e. check the continuity of the part ensure that there is no gap between the surfaces we can take the help of surface command for this. The next step is to create a dummy tooling axis from the centre point of the circular geometry on the…

REPORT: For the given Fan Cover catpart first we need to make the basic checks i.e. check the continuity of the part ensure that there is no gap between the surfaces we can take the help of surface command for this. The next step is to create a dummy tooling axis from the centre point of the Fan Cover Class A Surface To…

BOM SR. NO. ITEM NO. DESCRIPTION QTY MAKE   P003_Z03_ST03_01_00 BASE UNIT 1x   1 P003_Z03_ST03_01_01 WELD FRAME 1x    2  P003_Z03_ST03_01_01.1 BASE PLATE 1x MFG 3 P003_Z03_ST03_01_01.2 SQ TUBE 50×50×2×L810 2x   4 P003_Z03_ST03_01_01.3 SQ TUBE 50×50×2×L1510 2x   5 P003_Z03_ST03_01_01.4 SQ TUBE 50×50×2×L710 1x   6 P003_Z03_ST03_01_01.5…

What are the Drawing templates? Drawing Templates are basically the drawing standards as per customer’s specifications. Drawing Templates are format that are used for detailing of different parts or units of the fixture. There are ‘n’ numbers of details, that are already available on the template &…

AIM: To perform 3D finish and design Rough locators for the Fixture assembly design.   3D FINISH: 3D finish is a process where the design is being completely finish and to be ready for final simulation & 2d detailing.These is the process before sending the part for final simulation. In these process…

What do you understand by the 3D finish process? 3D finish is a process where the design is being completely finish and to be ready for final simulation & 2d detailing.  These is the process before sending the part for final simulation. In these process the parts are checked for proper clearance and the nominality…

AIM: To design a Base Unit with complete fixture assembly.   BASE UNIT: A base unit is the unit designed to mount all the other units (Clamp unit, Pin unit, rest unit etc ., ) of the tool, also other parts necessary for a tool like pneumatic valve box, trunking cable path will also be mounted on to a base unit. The…

AIM: To design and understand the concept of Swivel Clamp Unit & Pin Clamp Unit.   CLAMP UNIT: A clamp unit is a unit designed to clamp/hold the car panel with NC blocks/Mylar/Rest by using a pneumatic clamp cylinder.  The different parts of a clamp unit are:-  Clamp Mylar/Finger: Finger is a NC…

What is the Base Unit? What are the typical parts of the Base Unit? A base unit is the unit designed to mount all the other units (Clamp unit, Pin unit, rest unit etc ., ) of the tool, also other parts necessary for a tool like pneumatic valve box, trunking cable path will also be mounted on to a base unit. The parts of…

AIM: To design and understand the concept of Power Clamp Unit & Rest Unit.   CLAMP UNIT: A clamp unit is a unit designed to clamp/hold the car panel with NC blocks/Mylar/Rest by using a pneumatic clamp cylinder.  The different parts of a clamp unit are:-  Clamp Mylar/Finger: Finger is a NC Block…

AIM: To design and understand the concept of Fixed Pin unit and Retractable Pin unit. Components of a Pin Unit: Pin:  Pin is a part which locates the car panel. A pin can either be a make part or a standard part. Pin should have grinding surface on shaft with fits on to which the pin retainer will be fitted. The mounting…

What is Design Methodology? Design methodology is the steps followed during the concept designing stages of fixture design. Purchase Order: Purchase order is the order from customer for start of work. It is basically a confirmation from the customer side, that we are ready to start the designing or, go ahead. …

What is the process of project execution activity? RFQ (Request for Quotation): RFQ is request for quotation where in a customer gives his requirements, specifications, etc in form of document or data to study or work on it and give the commercial offer, technical offer, timeline of the project to the customer. 1st…

Answers in attached word file

   Procedure followed to route the wiring harness on V16 engine: Download the connector & clip 3D data from www.te.com Create the required geometrical parameters such as points and axis system  Define parts as connectors from electrical part design workbench Define bundle connection point Define…

  Harness Continuity Check:   Flatten View:     Procedure followed to route the wiring harness on Car Back Door: Download the connector & clip 3D data from www.te.com Create the required geometrical parameters such as points and axis system  Define parts as connectors from electrical part design workbench Define bundle…

    Procedure followed to flatten the wiring harness assembly: Open the wiring harness assembly product file Create new product and name it as flatten harness Go to electrical harness flattening workbench Click on harness flattening parameters and input all the parameters Extract the harness assembly product…

Procedure followed to route the wiring harness : First download the connector 3D data for all connectors from www.te.com Create the required geometrical parameters such as points and axis system  Define parts as connectors from electrical part design workbench Define bundle connection point Define connector connection…

  Procedure followed to route the wiring harness : Download the connector 3D data from www.te.com Create the required geometrical parameters such as points and axis system  Define parts as connectors from electrical part design workbench Define bundle connection point Define connector connection point Create…

Procedure to define P clamp as electrical support: Get the clip 3D part from te.com Define the geometrical parameters such as points and planes Define part as support Define entry point and plane Define base and exit plane     Procedure to define backshell as electrical part: Get the backshell 3D part from te.com…

    Procedure followed to create the CPU Fan Bezel mold blocks: Decide tooling direction and check for draft analysis Scale the model considering 0.6% shrinkage i.e. 1.006 Make the parting lines using parting line command Close the open surfaces using shut off surfaces and knit them Create the parting surfaces…

    Procedure followed to create the Plastic Knob mold blocks: Decide tooling direction and check for draft analysis Scale the model considering 0.6% shrinkage i.e. 1.006 Close the open surfaces using shut off surfaces, keep the bottom open surfaces as no-fill. Use loft surfaces for closing no-fill portion and…

  Procedure followed to create the mold: Decide tooling direction and check for draft analysis Scale the model considering 0.6% shrinkage i.e. 1.006 Split the model using split line command and create the parting lines Close the open surfaces using shut off surfaces. Use ruled and loft surfaces for closing rib portion…

  Procedure followed to create the mold: Decide the tool direction Using draft analysis check for draft on each surface Decide the core and cavity side of the mould Scale up the model considering 0.6% shrinkage i.e. 1.006 Using parting line command create appropriate parting line Cover the holes present in model using…