Week 8 - Challenge 5 - Core & Cavity Design

Aim: To design a Back Door using given Styling "Class A" Surface. Introduction: Back Door: The backdoor or tailgate is the rear most part of the automobile which opens upwards,downwards or sideways to give access to the luggage space or seating area. In most of the cars the backdoor opens upwards. It is hinged to the roof…

Aim: For the given roof styling, develop the essesntial flanges and reinforcements, provide appropriate dimensions and check for draft analysis and to perform roof curvature study using NX-CAD Introduction: Roof An automobile roof or car top is the portion of an automobile that sits above the passenger…

Objective: To design the car front fender with the help of using skin data (Class A surface) shared by the styling team and make it ready for manufacturing with mounting flanges using NX CAD Introduction: Fender: Fender is a part of the vehicle that frames the wheel . The primary purpose of the fender is to prevent sand…

Aim: Using the Section from the Hood design and calculate the section modulus and compare it with a new section with higher sectional modulus for optimization. Sectional Modulus: Section modulus is a geometric property for a given cross-section used in the design of beams or flexural members. Sectional modulus is a direct…

Question 1 What is the difference between mapped and dynamic model of engine, motor and generator? How can you change model type? Power Train block set provides two types of combustion engine Model. One is 'Mapped' and another one is 'Dynamic' Mapped Engine Mapped engines represent macro engine behavior as a set of lookup…

Objective: To Design hood outer panel, inner panel and reinforcements with the given outer hood skin, master section and design parameters. Introduction: HOOD The hood or bonnet is a hinged cover over the engine of motor vehicles that allows access to the engine compartment, or trunk for maintenance and repair. The inner…

UnderBody Coating The Under body Coating is a protective layer applied to the BIW of the car to protect it against small stones, dirt etc. to damage the paint. It also helps in corrosion resistance of the metal and prevent rusting.   Types of under coating 1. Rubberized Under Coating It is easy to apply and offers…

Aim: To provide a suggestion for buying a car for the following case study using Benchmarking Case given:  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, five-year-old boy, his father, and his mother. He visits…

FINAL PROJECT - SIDE DOOR TRIM PANEL AIM: To Develop a CAD model of a door trim panel with the given Class A surface and Master section input with its attachment features as per standard design guidelines in the industry. INTRODUCTION:  To create a new product various steps are involved in the automotive industry…

Aim:  To design B-pillar with flanges, Screw bosses, and Ribs with given Class A input.   Class A   Tooling Axis     Tooling axis is created on the basis of the two master sections by ‘Bisecting method’ and draft analysis.                    (Draft…

Objective : To Desing 3D parts of given 2D sketch of Quick Return Mechanism and CV Joint and Assemble them using Assembly Design. Quick Return MechanismBelow Images show the isometric View of the 3D parts of given 2-D sketchPart 1Part 2Part 3Part 4Part 5AssemblyAssembly is done on basis of Kinematic movement of each…

Aim:  To Create the Base Bracket Plastic component through the given Class-A surface . Also, Creating the Heat Stakes and the locators considering the design rules mentioned in the video for the door applique.   INPUT Applique & Door Attachment Tooling axis Creating the tooling axis with reference to the…

OBJECTIVE: To Create the Screw Boss and Dog House for the Centre console coin holder considering the design rules   SCREW BOSS WITH RIBS Screw boss is created with ribs considering for its structural support Intersection View It seen that the ribs and screw boss is designed considering desgines rules of 40% wall…

 ISOMETRIC VIEW   All the design rules are met while creating the ribs it shown in detail below.   12.5 mm is the maximum height the rib can be and it is followed as given. Minimum thickness at the top Minimum thickness is 0.75mm and this design has cleared the minimum thickness. Minimum thickness at the…

CLASS A SURFACE CLASS C CLOSED SURFACE DRAFT ANALYSIS (All the features are cleared for minimum draft angle of 2.9 degrees along the tooling axis) CORE CAVITY PARTING SURFACE WITH COMPONENT Parting surface is the connection surface between CORE & CAVITY PARTING LINE WITH COMPONENT AND PARTING SURFACE Parting line is…

CLASS A SURFACE TOOLING AXIS It is created perpendicular to the base surface of the pocket as it is the obvious direction of a tooling in manufacturing.    CLASS B SURFACE B Surface is created with offset distance of 2.5mm  outwards from the Class A Input CLASS C SURFACE Connection between the CLASS A &…

CLASS A SURFACE TOOLING AXIS Since this component is little complex and has more phases. It is diffcult to tool the whole component with the one tooling axis. Below main toolig axis is made to clear the features of clearance draft angle durig draft analysis. (Vertical axis) Since side phases, does not clear the minimum…

Tree Structure with Thickend Body CLASS A SURFACE CLASS B SURFACE CLASS C SURFACE with Tooling Axis Tooling axis is created using the 'Bisecting Method' which intersects the point center in the base surface feature horizontally and vertically. Each intersect outcomes a bisecting line in which the 2 lines of the horizontal…

Tree structure with Thickened Body CLASS A SURFACE CLASS B SURFACE CLASS C SURFACE with Tooling axis Tooling axis is created using the 'Bisecting Method' which intersects the point of the top hole and the tooling axis line created by 'bisect' line command. DRAFT ANALYSIS A minimum of 3'degree draft angle is given while…

Draft Analysis:  It is made to ensure that the component has the clearance draft angle correct for ease of ejection of the part in the manufacturing process.  Tooling axis : Tooling axis is a reference line where the draft angle of a feature is created on the basis of this tooling axis Isometric View Bisecting…

AIM:   To cleanup the geometry and mesh for the given components using HyperWorks   Procedure: (Pre processing) Import the CAD model or in this case open the .hm model file Cleaning up the geometry - delete unwanted lines, points,nodes.Also delete the solids, then check for free(red) and T-edges(yellow)…

ANSWER MODEL: https://drive.google.com/file/d/1Z0mETZX0cCgFcO6OmSh8iF9Tw40G1AtP/view?usp=sharing  

MODEL: https://drive.google.com/file/d/1o3say05IWze17gCEoACgXbSJWVATZWbt/view?usp=sharing Aim: To check for the geometrical errors and mesh the given component with tetra element for stated Quality criteria. Procedure: Make a topo for all of the component to stitch any surfaces and check for ‘Geometry’ errors…

ANSWER MODELS: https://drive.google.com/file/d/1VDps3QVvmdUxGXTD7VCzuTnrDoLkEiQw/view?usp=sharing   https://drive.google.com/file/d/1VfJ7lSQV5Rua_XD__pjNGXha84NqgCro/view?usp=sharing  

Aim: To check and correct geometry errors in the given bottle cap component. To mesh the given component and assign thickness. Procedure: Performing a topology for the given whole component to stitch any uneven joints and check the quality From the ‘checks’ option geometry check is followed for visible errors.…

WOT (Wide Open throttle)  Wide open throttle (WOT) refers to an internal combustion engine's maximum intake of air and fuel that occurs when the throttle plates inside the carburetor or throttle body are "wide open", providing the least resistance to the incoming air. Given Vehicle Paramaters:…

Drive cycle A driving cycle is a series of data points representing the speed of a vehicle versus time. Driving cycles are produced by different countries and organizations to assess the performance of vehicles in various ways, as for example fuel consumption and polluting emissions.      …

AIM: To simulate the working of washing machine by stateflow and highlighting the process with LEDs for given conditions Given Condition  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…

Aim: To simulate a gear shift scenerio with change in speed using simulink chart   Introduction Gear Shift: A gear stick , gear lever , gearshift or shifter  is a metal lever attached to the shift assembly in a manual transmission-equipped automobile and is used to…

Aim: To On & Off a fan with a threshold temperature using thermistor. Given condition:  'ON if the temperature above 25 °C, OFF otherwise'   Introduction: Thermistor A thermistor is a type of resistor whose resistance is dependent on temperature, more so than in standard resistors. The word is a…

Aim: To simulate a doorbell model using solenoid block in Simulink   Theory In a physical scenerio, a door bell circuit consists of a battery, a switch, a solenoid and a lever. A metal bell is placed near the bell. When the lever hits the metal bell , thus produces a sound. When the switch is pressed, the circuits…

AIM: File parsing a thermodynamic data from the given and analysing the data Objective:  To write a function that extracts the 14 co-efficients and calculates the enthalpy, entropy and   specific heats for all the species in the data file.  To Calculate the molecular weight of each species and display…

AIM: To find the global maxima of a stalagmite function using Genetic Algorithm in MATLAB   Theory: Optimisation     Mathematical optimization or mathematical programming is the selection of a best element (with regard to some criterion) from some set of available alternatives. It can be done…

Aim: To simulate a curve which best/perfectly fits for the given data using MATLAB   Introduction: Curve fitting      Curve fitting is the process of constructing a curve, or mathematical function, that has the best fit to a series of data points, possibly subject to constraints. Curve fitting…

AIM: To simulate the transient behaviour of a simple pendulum and to create an animation of it's motion.   Theory: The Simple pendulum        A point mass / bob attached to a light inextensible string and suspended from fixed support is called a simple pendulum. The vertical line passing through…

Objective: To plot and P-V diagram(Otto cycle) and determine the thermal                    efficiency   Theory: Otto cycle:          Otto cycle is an idealized thermodynamic cycle that describes the functioning of a typical…

Aim: To simulate the forward kinematics of a 2R Robotic Arm Objective : To Animate the motion of the Robotic Arm and making a                                video using MATLAB   Description: 2R Robotic Arm:         …