Week 9 - Challenge 3 - Bumper

Wiring Harness Installation on given Tailgate body AIM: To prepare the wiring harness for the given tail gate body and apply protective coverings. Prepare the flattened drawing for the wiring harness.PROCEDURE:Create a product file named "Assy_wiring_harness_tailgate", add the tailgate body and a geometric bundle…

Wiring Harness Engine Assembly - Project 1Aim: To Route the Wiring harness on Given Engine and Prepare flattened view drawing in CATIA V5. Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required.Introduction:A wiring…

Aim: Place the flattened view of week 4 challenge on drawing sheet.procedure:1. Open a drawing file in catia mechanical design.2. Place front view in sheet using the resting plane of the connector as shown below.3. Flattened drawing shown on the sheet is shown below.Conclusion: Flattened view is shown in the sheet drawing…

Creating  a Bracket with features using NX Introduction: Sheet metal gussets are formed with special tooling which has a ridge going across the v opening.  The punch is split to the left and right of the ridge as to not be damaged while forming.  The sheet metal is bent normally across the v opening except…

Design of given Harness Layout using Electrical Workbench 1. Harness layout B Define Catalogue and add electrically defined parts to family harness B: Add all the parts in electrical harness assembly, position them and add annotations: Join all connectors using harness bundle as given in diagram: Add protective covering:…

Electrical Harness Assembly Aim: To Route the given harness layout in Electrical workbench and report the step by step process. Assembly in Workbench Define all given connectors as electrical components, geometric orientation and connection points. Use Electrical Harness Assembly. Recreate given route in a Multibranchable.…

1. Download following cad data & define it as Electrical support using Electrical Part design Workbench. Define all the necessary properties. Create the solid part using closed surface. Create entry point on one side using point definition: centre of circle Create plane tangent to surface on entry point. Create exit…

AIM:- To Download following connectors & Connector clip cad data from given link & define it as Electrical Connector using Electrical Part design Workbench. Define all the necessary properties to Connectors & Clip 1. Deutsch DT06 – 08SA : 2. Tyco 174357-2 : 3. Tyco 85229-1 :  Assembly of…

Underbody Coating In Indian road conditions, a cars underbody is most prone to corrosion. 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 not physically accessible but are prone to corrosion.Benefits•…

Creating a Bracket Using NX Objective To creat a bracket with given drawing and directions. To draft the Metal. Introduction A metal bracket is a fastener or connector designed to secure and hold two pieces or objects together. They are used to support shelves, stabilize equipment, fasten uprights, or serve as decorative…

Creating an odd shaped enclosure OBJECTIVE: To create an odd shaped enclosure with beads, holes and other features in the sheet metal. To Draft the flat pattern with annotations. INTRODUCTION: Sheet metal is metal formed into thin, flat pieces, usually by an industrial process. Sheet metal is one of the…

Box Assembly Using NX CAD Sheet Metal Tools OBJECTIVE: To draw a 3D model of a sheet metal box as per the dimentions given and draft a flat pattern. INTRODUCTION:  Sheet metal parts are widely used in machines, enclosures, brackets, and automomotive applications due to its various advantages. The parts are normally…

 CASING DESIGN USING NX CAD Draw the Rectangle of 50 x 60 mm in XY plane. Create a tab of 1mm. Draw a rectangle of dimentions 40 x 5mm with one side coincident to the 50mm side of the tab. Make a Normal Cutout. Draw two lines parallel to and at a distance of 10mm from the 60mm side of the tab. Use the lines to create…

A-PILLAR WITH MASTER SECTION 1. SKETCHES AND TOOLING AXIS    The Tooling Axis is created by using the symmetric points in the master section is shown below.   2. TREE STRUCTURE   3. 3D-CAD PARTBODY   4. DOG HOUSE ATTACHMENT 5. DRAFT ANALYSIS

AUTOMOTIVE SHEETMETAL ROOF DESIGN USING NX CAD 1 INTRODUCTION       The objective of this project is the design and modeling of the Body-in White Roof with all design condiderations and calculation. The Car Roof serves the purpose of protecting the passengers from Weather Conditions and Accidents. The…

DESIGN OF HEAT STAKES AND LOCATORS 1. Introduction       Heat staking also known as thermoplastic staking is the process of joining two dissimilar materials together. In heat staking we use local heating and cooling to raise the temperature of plastic components and allow plastic reforming to be carried…

Door Trim - Dog House Design 1. Dog House - Introduction       Dog houses are true to their name similar in structure to actual dog houses. However, the dog houses are created with a thinner tip attached to the main component. The main purpose of which is to protect the visible surfaces from defects such…

RIBS AND SCREW BOSS CREATION 1. Tooling Axis and Draft Analysis The Tooling Axis is created by taking the center point created by the bisecton of two lines on the surface. Axis is parallel to Y-direction. The Draft Analysis as shown has all part surfaces >3deg. The ribs and screw boss have a draft of 0.5deg. The Thickness…

BUMPER DESIGN FROM CLASS A SURFACE 1. Tooling Axis       The side bumber cover given in the part file has features with cutouts to fit the front radiator and headlamp. Tooling axis for this part is decided after considering the ease of removal after deep drawing/ blanking. The relatively flat part between…

Switch Bezel Design  1. Introduction Switch Bezels in car are parts which contains switches and controls for different functions like Window control, Door lock/Unlock,Media and Temperature controls. Acrylonitrile Butadiene Styrene(ABS) is used in switch bezel.which is scratch-resistant and wear-resistant.…

BASE BRACKET DESIGN - TOOLING AXIS AND CLASS C SURFACE 1.1 Tooling axis creation with Part Tree Structure(PTS) The Point 2 is located by the center point of the locating hole. Point 2 is used to crate a plane 1 parallele to ZY plane. Plane 1 is used to intersect the Class A surface. Two Angular lines on the Profile are…

CONSTANT VELOCITY JOINT   OBJECTIVE: Create an assembly of CV Joint using the given 2D Drawings.   PROCEDURE:  Create a sketch using dimensions from the drawing and pad them to get a 3D model. Note: a point at origin is created and all sketchs are projected from this point. The three parts (Connector…

BACK DOOR DESIGN Introduction The Back Door of an Automobile, also called the Tailgate, is on the backside of the Car. It is the door to the luggauge compartment, a passenger shield against rear collisions and weather, the backside wind shield, the Rear Window housing and the Rear Wiper Motor Housing. Back Doors are less…

FRONT FENDER DESIGN Fender is the side covering above the wheel of the automobile. It protects the engine compartment from mud, stones and gravel that the tyre will throw out when rolling on the road. Front fender plays a role in the asthetics, protection of engine compartment, protection of pedestrians and finally also…

FRONT FENDER Fender is the American English term for the part of an automobile, motorcycle or other vehicle body that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other road spray from being thrown…

A BRIEF ABOUT SECTION MODULUS Section Modulus is defined as the Area Moment of Inertia divided by the Distance between Neutral Axis and the Boundary or Extreme End of the Body/Section.  `S=I/(y)` where, I = Moment of Inertia of the Section,           y = Distance between  Neutral…

HOOD DESIGN - CHALLENGE The different parts of the Hood Design are classified into: Hood Outer Panel Hood Inner Panel Striker Hinge There are many aspects to design of BIWs Hood leading to Weightlessness, Geometrical Accuracy, Aesthetics, Driver Safty, Pedestrian Safty and Ease of Manufacturing. As covered in the Video,…

3D Model Front View: Side view: Top view: Trimetric view: Draft/2D Drawing:  

BENCH-MARKING Benchmarking involves a structured comparison between similar products, services or processes on some dimensions of performance. For example it can be used to compare the availability and delivery of features in a product and in this form often provides the basis of consumer tests and reviews. These look…

INTRODUCTION: File parsing is the process of reading computer files and compiling data from those files through the means of a programming language. A data file containing ordered and spaced elements of repeating pattern can be read through the compiler. The compiler must be able to modify and create files and have a preconcieved…

GENETIC ALGORITHM: INTRODUCTION Genetic Algorithm is a method of optimization of an objective function based on the Natural Selection Principle or Survival of the Fittest. It is used to find the minimum or maximum of the objective function through the following steps: Set Initial variables. Define Objective Function and…

EXPLANATION: BASIC PRINCICLE AND FORMULA: The Basic 2nd Order Ordinary Differential Equation for the motion of a pendulum is                    This is simplified to Equation 1 and 2 respectively, Theta1 = d(theta)/dt and (d(theta1)/dt)+(b/m)*theta1+(g/L)*sin(Theta)=0. Where, b-damping, m-mass, g-acceleration of gravity,…

Explanation of the Program: Basic Math and Principles of the Program. The robotic arm consists of 2 links and a tool to complete a job at one end. Link 1 is of length l1=1.0 and Link 2 is of length l2=0.5. Link 1 (x0,y0 and x1,y1) is fixed at the origin and it's angle with the x axis is `theta1`. (x0,y0)=(0,0). x1=l1*cos(`theta1`)…