Week 8 - Challenge 6 - Core & Cavity Design

CPU Fan Bezel MOLD ASSEMBLY DESIGN:  INPUT:      OUTPUT:                 The procedure for achieving the output included creation of  Core and Cavity surface bodies Core and Cavity Blocks Sliders  Inserts (on both core and cavity side) Ejection system i.e. Ejector pins, ejector plate and support plate. Sprue, Runner and…

PLASTIC KNOB DESIGN FOR EJECTOR PINS, EJECTION PLATE, BACK PLATE, SPRUE, RUNNER, GATE, AIR VENTS AND COOLING CHANNELS. INPUT:    OUTPUT:      STEPS FOLLOWED: Ejector Pins, Ejector Plate and Back Plate:  In Core Block, Sketch is made for Ejector pins of 6mm diameter. Using Core command the…

CPU fan case SLIDER and INSERTS:    INPUT:      OUTPUT:   SLIDERS: Yellow INSERTS: Blue CORE: Red CAVITY: Transparent block (originally in green)         Procedure for Sliders:  For SLIDER01 in core block, sketch is done which surrounds the undercut part with hole.…

TABLE FAN BASE MOLD ASSEMBLY:   INPUT:      OUTPUT:         Procedure of Core/Cavity block for TABLE FAN BASE: Component is SCALED as per the product shrinkage percentage (in this case 0.6%) and DRAFT ANALYSIS is performed so that parting line can be forme       …

Door Bezel Sliders design:                     STEPS Followed:  Creating Slider sketch using existing geometries and using SPLIT command in Cavity steel part to form initial separate slider body. Saving above part obtained as separate entity. Creating New part…

PROJECT 2: PROJECT 2 CAD Zip Gdrive Link        STEP 1: Gun Study Weld gun study is done so that no fixture comes in way of weld gun during spot welding operation. This decides the placement of various units.  METHODOLOGY: Gun tip is placed on each spot and oriented normal to the weld surface. This is performed for each…

BOM: A Bill of Materials (BOM) is a comprehensive list of all the components, parts, materials, and sub-assemblies required to manufacture a product. It provides detailed information about each item, such as part numbers, descriptions, quantities, and sometimes even costs.         BOP:

SWIVEL CLAMP UNIT 1:                          SWIVEL CLAMP UNIT 2:                             SWIVEL CLAMP UNIT 3:                         PIN UNIT:           

DRAWING TEMPLATES: A drawing template is sheet layout inside on which 2D drawing views are made. A drawing template is usually consist of offset Border line having grid references and unit measurement references mark. A title box is also present at lower right side which contains information regarding Sheet name, Sheet…

BIW FIXTURE ASSEMBLY:       PIN UNIT:               BASE UNIT:                              

Input from previous challenge:  Fig.1    BIW FIXTURE WITH 3D FINISHING AND ROUGH LOCATORS: Fig.2    3D FINISHING PROCESS pointers: HOLE CONCENTRICITY: Every holes (dowel, pin, and screw hole) should be concentric with respective mounting body holes.Fig.3  MACHINING AREA: Area to be machined…

3D Finish process is the process where the design is beign completely finished and to be ready for final simulation and 2-D detailing. Points to considered while finishing a design:  Hole Concentricity and hole sizes : Making sure each and every dowel as well as screw holes in two mating parts concentric.The sizes…

BIW fixture assembly: The four clamp units arrests the translation about Z-axis and the rotational movement about Y-axis and X-axis. The Two Pin units around the center of component arrests the translation about X-axis and Y-axis as well as the rotational movement about Z-axis   Image.1 NOTE: The orientation of axis…

1. BASE UNIT:  A Base unit refers to component or structure that serves as a foundation for the entire fixture assembly. It is a key element used to support and locate the vehicle body or body components during the manufacturing or assembly process.    PARTS OF BASE UNITS: Base Plate: Machined plate of 25…

CLAMP UNITS AND PIN UNITS ASSEMBLY: Total Clamp units: 4Types of Clamp units:3 Total Pin units: 2Types of pin units: 1     NOTE: Each of the three clamp units are having identical clamping cylinder. Also both the pin unit is having identical cylinder too. All headed screws used for assembling various parts of clamping…

 CLAMP UNIT:   A Clamp Unit is used to lock the panel position in transitional direction. It supports the panel with fixed Mylar and lock its movement with mobile Mylar, when panels come onto the tool then clamp is in open condition once panel sits down then clamp closes and joining process is done. Once…

FIXED PIN UNIT: An assembly of standard and manufacturing parts consisting location pin is called Pin unit. A pin unit in which pin’s position is fix, is called Fixed Pin Unit. Pin unit is used to lock the rotational position of panel.  Round Pin is  used to control panel in two directions while Diamond Pin is used to…

1. Design methodologies is nothing but the steps followed during designing stages of fixture design Design methodologies are :  Purchase Order Inputs from customer Percentage completion criteria Design output   2. Inputs required from customers in fixture designing are:  Functional requirements Preferred…

1. PROJECT EXECUTION ACTIVITY: STAGE NO. STAGE PROCESS 1 RFQ required RFQ stands for "Request for Quotation". Customer lists its requirements in form of data. 2 1st specification discussion meeting Customer requirements are studied. Documents are prepared like technical offer, commercial offer, time duration, etc. 3 Offer…

1. BIW (Body in white): BIW refers to the stage in automobile manufacturing in which the vehicle body sheet has been assembled. This means that the vehicle’s body frame has been joined together including doors, hoods, trunk, bumper and deck lights. At this stage all the chassis assemblies are welded together before…

ENGINE WIRING HARNESS:     ENGINE WIRING HARNESS FLATTENING:      FLATTEN DRAWING OF ENGINE WIRING HARNESS:

BACKDOOR WIRING HARNESS ASSEMBLY:     BACKDOOR WIRING HARNESS:     FLATTENED BACKDOOR WIRING HARNESS:     FLATTENED BACKDOOR WIRING HARNESS DRAWING:     BACKDOOR WIRING HARNESS CATALOGUE:

Wiring harness Assembly:     Wiring Harness Flattening:   Harness Flattening Drawing:

HARNESS ASSEMBLY:         HARNESS A:     Bundle segment fully connected:       HARNESS B:     Bundle segment Error:     Branching point Adjusted for error solving:     Bundle segment fully connected:       CATpart file:

Wiring harness assembly:   Electrical definition of Connectors:

1. P-CLAMP: Defined geometries: Entry Plane Entry Point Exit plane Base plane   Clips Catalogue:     2. BACKSHELL: Defined geometries: Backshell Connection point Bundle Connection point Backshell Catalogue:     3. Corrugated tube (35mm OD, 1.5mm Thickness):   Corrugated tube (20mm OD, 1.5mm Thickness):   Corrugated tube…

MALE CONNECTOR C-DT06-08SA: No. of Terminals: 8 Points defined: Bundle connecting point Connector connecting point     FEMALE CONNECTOR C-2-174357-2: No. of Terminals: 3 Points defined: Bundle connecting point Connector connecting point Cavity Connection point     CAVITY CLIP C-0085229-01-3: Points defined: Cavity point…

Butterfly Valve Assembly:     Butterfly valve assembly with dimensional and geometrical tolerances:

BACK DOOR: OUTER PANEL:   INNER PANEL:   INNER PANEL WITH REINFORCEMENTS:   WIPER MOTOR REINFORCEMENT EMBOSS:   HINGE REINFORCEMENT EMBOSS:   GAS STAY REINFORCEMENT EMBOSS:   STRIKER REINFORCEMENT EMBOSS:     TOOLING AXIS: It is created by bisecting two lines (solid thin lines) taken…

ROOF WITH REINFORCEMENTS:       BOW ROOF CALCULATIONS: W = [1.73 x 10^(-3) x L] + [1.85 x 10^(-8)  x (R^2)/t] + [ 1.10x10^(-3) x l] - 2.68 Where, L = Roof Length in X-Direction[mm](Roof dimension in 0-Y) R = Roof curvature       R = 2(Rx*Ry)/(Rx+Ry) Rx = X curvature Ry…

FENDER: A fender is the curved portion of the car's body that sits over and houses the wheels The purpose of a fender is pretty simple. Its purpose is to keep mud, rocks, and other road debris from being thrown around by the tires. In other words, the fender is a housing for the wheels that keeps road debris contained.…

EUROPEAN REGULATIONS REQUIREMENTS: European regulation requires minimum clearance (L) of 10mm in between fender and tyre profile. At five sections mentioned below.   Lines intersecting the tyre circle and Fender projection are Section B, Section C, Section D and Section E (in Clockwise direction from left) as shown…

WHAT IS SECTION MODULUS? The section modulus of the cross-sectional shape is of significant importance in designing any structure. It is a direct measure of the strength of the structure. A Structure that has a larger section modulus than another will be stronger and capable of bearing greater loads.    …

BIW HOOD DESIGN ASSEMBLY:   WHAT IS BIW? That stage in automotive design or automobile manufacturing in which the car body sheet metal components are assembled by any means like welding, riveting or bolting, etc. is called BIW (Body In White). Moving parts such as Door, Hood, Trunk Lid, Front Fender, and the components…

UNDERBODY COATING:   It is a thick cladding (typically made of rubber) that is placed uniformly to the car’s underside. Underbody coating provides long term protection from corrosion to car’s underbody. It also protects parts like internal body panels, frame rails and other inner cavities that are…

BENCHMARKING:  Benchmarking involves a structured comparison between similar products, services or processes on some dimensions of performance. Benchmarking is a process used to measure the quality and performance of your company’s products, services, and processes. These measurements don’t have much value…

DOOR TRIM ASSEMBLY: PARTS: S.NO. PART NAME REPRESENTAION COLOR QUANTITY 1 LOWER SUBSTRATE Pink 1 2 ARM REST Green 1 3 MID SUBSTRATE Orange 1 4 MAP POCKET Beige 1 5 PUSHCLIPS Light Green 2       ASSEMBLY TREE STRUCTURE:        FRONT & BACK VIEW:       TOP & BOTTOM…

MODEL 1: QRMM         MODEL 2: CV JOINT

A-PILLAR :

DOOR TRIM with HEAT STAKES and LOCATORS:           TOOLING AXIS CREATION: Tooling axis is created in y-direction and is passing through centroid of extracted surface (light colored) of CLASS A surface.           DRAFT ANALYSIS:  GREEN COLOR: shows ejectability of component…

DOOR TRIM WITH DOGHOUSES:             TOOLING AXIS CREATION: STEP 1. Surface is chosen based on its ability to create intersect which can pass through the steepest surfaces of the CLASS A. That surface is then EXTRACTED and centroid is taken which will be point through which tooling axis will…

DOOR HANDLE WITH SCREW BOSSES and RIBS:                     DRAFT ANALYSIS: 1. Input: CLASS A and TOOLING AXIS: GREEN color shows surfaces with no deformation during mold removal.     2. Input: DOOR HANDLE BODY and TOOLING AXIS: GREEN colored surfaces…

LOWER DOOR TRIM all views:      TOOLING AXIS: TOOLING AXIS (dotted line) is taken normal to extracted surface from CLASS A (Cyan colored) and is passing through centroid of extarcted surface.       DRAFT ANALYSIS:  1. Input: CLASS A SURFACE and TOOLING AXIS GREEN COLOR shows the…

SWITCH BEZEL: RED dotted line is the TOOLING AXIS which shows the direction of cavity block movement. YELLOW dotted line around the body is Parting line which separates the boundaries of core and cavity block. CYAN colored body is the fixed CORE BLOCK. BROWN colored body is the movable CAVITY BLOCK. BLUE colored body is…

            TOOLING AXIS: Tooling axis is created in direction normal to the number plate plane on front side of bumper passing through a distance of 125mm in Z-direction to its centroid.           DRAFT ANALYSIS:   1. INPUT: CLASS A and TOOLING AXIS The component…

        TOOLING AXIS CREATION: INPUT: CLASS A SURFACE BISECTING METHOD:  1. Extracting BIN FLOOR surface, then taking point in centroid for defining tooling axis origin and assigning axis system at that point. 2. Intersect 1 is formed in Z-direction and closest surface (in terms of least draft…

  As shown above, the draft angle of 3deg (approx) on shown surface was achieved through adjusting angle of Line5 in Tree structure from 3deg (standard nominal draft angle) to 4.7deg as shown below. Change from 3deg to 4.7deg while creating tooling axis was because for 3deg in draft analysis the surface shown above…

        QUESTIONS REFARDING THE METHOD FOR ABOVE CAD IN #35 VIDEO: 1. WHY SYMMETRY NOT USED FOR RIB 2 ? 2. WHY CONSTANT FILLETS OF 5.5mm USED AROUND RIBS IN CLASS B SURFACE WHEN SOME OF THEM WERE INSIDE AS WELL AS OUTSIDE EDGES w.r.t CLASS A SURFACE. FOR INSIDE EDGES 3mm-2.5mm =.5mm OF FILLET BE GIVEN…