Week 9 - Project - Master Section Development

Aim: To route the wiring harness around the given car body part and prepare a flatten view drawing in CATIA V5. Objective: To download the 3D CAD data for connectors from TE Connectivity website. Define the connector data as Electrical Part in CATIA V5. Prepare a catalogue for all the components of harness assembly. To…

Aim: To route the wiring harness on the given engine and prepare a flatten view drawing in CATIA V5. Objective: To download the 3D CAD data for connectors from TE Connectivity website. Define the connector data as Electrical Part in CATIA V5. Prepare a catalogue for all the components of harness assembly. Place the safety…

Aim: To create the flattened geometry of the wiring harness bundle as per given drawing and create a drawing sheet for the flattened harness.   Theory: The given wiring harness drawing is shown below. It is the same drawing which was used to create the wiring harness in the earlier project.     Fig. 1: Given…

Aim: To create two different harness bundles as per given drawings and create a final assembly of those bundles. Objective: Define the given connectors as electrical components. Create a wire harness bundle separately as per given drawings. Check for bundle continuity. Generate CATPart from Product. Theory: The harness…

  Aim: To create a wiring harness by using the required connectors and following a given harness diagram. Theory: The given harness diagram is shown below:     Fig. 1: The given diagram to create a wiring harness.   In the above diagram 4 different types of electrical connectors are needed to be used.…

Aim: Assign the electrical properties to the given components and also create the protective coverings. Objectives: To assign the necessary electrical properties to the P clamp and define it as a support component. To define the given CAD data as Back Shell and assign necessary electrical properties. To create the protective…

  Aim: To define the given components as Electrical Connectors using the Electrical Design Workbench. Objective: To define the given components as Electrical Connectors using the Electrical Design Workbench. To define the necessary properties for the given connectors.   Theory: The given components were downloaded…

Aim: To create a 2D Mesh on the given sheet metal parts of an automobile Objective: Perform geometry checks and fix any errors. Create mid surfaces for the components of the given assembly and assign PID separately. Create a 2D mesh consisting of mixed elements. Follow the given quality for the mesh generation.  …

Aim: To design the back door assembly from the given Class-A surface.   Back Door: The trunk (North American English) or boot (British English) of a car is the vehicle's main storage or cargo compartment, often a hatch at the rear of the vehicle. It is also called a tailgate. In Indian English the storage area is known…

Aim: To design the roof assembly as per given master section. Calculate the feasibility of roof for the Heat Distortion and the Snow-load conditions. Also, perform the draft analysis on the components of the roof assembly.   What is an automobile roof? An automobile roof is a BIW sub-assembly which is mounted on top…

Aim: To design a half-bumper type fender from the given Class-A surface and follow the master section to create the drip area. Also, use the engineering principles to design the Sill Mount, Bumper mount and the A-Pillar Mount.   What is a Fender? A fender is the part of a car or bike, which frames the wheel well.…

Aim: To study the given model of the wheel arch design and conclude whether it adheres to the European Regulation for the design of the fender.     European Regulations: The European regulation for the fender design are shown below:   Fig. 1: European Regulations for the fender design According to the above…

Aim: To calculate the section modulus of the existing section at the center of the hood assembly. Also, suggest a way to increase the section modulus of the current hood assembly.     Section modulus is a geometric property for a given cross-section used in the design of beams or flexural members. Other geometric…

Aim: To design the hood assembly for a car using the given Class-A surface of the hood and the hinge and the striker assembly. Also, design the inner panel of the hood using the given master section.   Hood/Bonnet: Hood or Bonnet as it is known around the globe is the covering made of sheet metal and placed over the…

Under-Body Coating: Underbody coating is usually a dense cladding (often based on rubber) applied uniformly to the undercarriage of the automobile. It is normally sprayed or painted on when the car is just out of the dealership and is clean. But even if you are getting the undercoating applied after a couple of years,…

Aim: To benchmark vehicles based on their features and cost and suggest a suitable car for Mr D.S. Pughazhyendhii to suit his needs.   Benchmarking is the process of comparing the products’ features with the competitor and identify the improvements which can be done to make the new product better than the previous…

Aim: To create a Door Trim Assembly from the given Class A surface of the parts of the door following the OEM standards. Objective: To create Class B surface for each given part. To create Class C surface for each given part. To create solid body for each given part. Develop Master Section for each given part. Perform…

Aim: To create part models from the given 2D drawings for the Quick Return Mechanism and CV Joint, assemble them together appropriately, and create 2D drawings from the 3D part design.   Creating the Quick Return Mechanism Assembly: The quick return mechanism assembly is divided into 5 different bodies whose 2D drawings…

Aim: To develop the given Class-A Surface of the B Pillar along the Master Section, and create a solid body out of it. Also create the engineering features on the B surface side and perform the draft analysis.   The Class-A surface of the B Pillar is given as shown below: Fig. 1: Class-A with Master Section as given…

Aim: To create 2-Way and 4-Way locking pins and heat stakes on the given Door Applique part. Also create Class-B Surface and Class-C Surface on the given Class-A Surface and perform draft analysis on the Class-A surface and Final Body.   The Class-A surface of the Door Applique is given as shown: Fig. 1: Class-A Surface…

Aim: To create the tooling axis for the given Class-A surface of the Coin Holder and create a solid part along with Class-B and Class-C surface. Also create Ribs, Screw Boss and Dog House with reference to the design rules.   Procedure: The input model for the draft analysis is the class-A surface given by the class-A…

Aim: To create the tooling axis for the given Class-A surface of the Coin Holder and create a solid part along with Class-B and Class-C surface. Also create Ribs with reference to the design rules.   Procedure: The input model for the draft analysis is the class-A surface given by the class-A designers as shown below: …

Aim: To create the tooling axis for the given Class-A surface of the Switch Bezel and create a solid part along with Class-B and Class-C surface.   Procedure: The input model for the draft analysis is the class-A surface given by the class-A designers as shown below:  Fig. 1: Switch Bezel Class-A Surface…

Aim: To create the tooling axis for the given Class-A surface of the Coin Holder and create a solid part along with Class-B and Class-C surface.   Procedure: The input model for the draft analysis is the class-A surface given by the class-A designers as shown below:  Fig. 1: Class-A Surface of the Coin Holder…

Aim: To perform the Draft Analysis on the given Class-A Surface of the Door Arm Rest and also create the Class-B and Class-C Surface and make a solid body out of it. Procedure: The input model for the draft analysis is the class-A surface given by the class-A designers as shown below:  Fig. 1: Class-A Surface…

  Aim: To create the tooling axis for the given Class-A surface of the Switch Bezel and create a solid part along with Class-B and Class-C surface.   Procedure: The input model for the draft analysis is the class-A surface given by the class-A designers as shown below:  Fig. 1: Switch Bezel Class-A…

Aim: To create the tooling axis for the given Class-A surface of the Base Bracket and create a solid part along with Class-B and Class-C surface.   Procedure: The input model for the draft analysis is the class-A surface given by the class-A designers as shown below:    Fig. 1: Base Bracket Class-A…

Aim: To create the tooling access for the given fan cover model meeting the requirements of the Draft angle and perform the draft analysis on the model.   Introduction:  The modelling of plastic the component involves considering factors Draft ejectors side core lifters and undercuts. Is performed to ensure proper ejection…

  DESIGNING A SUNSEEKER PREDATOR YACHT   Aim: To design parts of a Sunseeker Predator Yacht, assemble the parts and create rendered images of the assembly in SOLIDWORKS 2020. Objective: Learn all the commands of part modelling as well as surface modelling Learn assembling the parts and complete the modelling…

DESIGNING AN AMERICAN CHOPPER IN SOLIDWORKS   Aim: To design the components of an American Chopper Bike, Assemble the components and create rendered images of the assembly. Objectives: Learn all the commands needed to design a component in SOLIDWORKS. Learn assembling the components and complete the modelling of the bike.…

Aim: To Simulate State flow model of a Washing Machine. To simulate a state flow model of a Gear Shift logic. Theory: A washing machine is an electronic system used to wash laundry. The term is mostly applied to machine that use water as opposed to dry cleaning. Washing machines are of two types: Semi-Automatic Washing…

Aim: To create a Simulink model to calculate the work done by the cutting tool of shaping machine. To create a Simulink model to solve the given equation Solve the given problems using ‘Mass-Spring-Damper in Simulink and Simscape’ example.     To find the work done by the cutting tool of shaping machine:…

Aim: To make a Simulink model of a doorbell using a solenoid block. To make a Simulink model to turn ON and OFF a ceiling fan by using a thermistor.   Objectives: To create a situation in which the switch of the doorbell is closed for 2 seconds and then released. To create a situation in which the fan is switched…

Aim: Write a MATLAB Code to run a Rankine Cycle Simulator and plot the T-s and h-s diagrams for the given data. Also, print the values of the state point variables in the command window. Rankine Cycle: The Rankine cycle is an idealized thermodynamic cycle describing the process by which certain heat engines allow mechanical…

Aim: Write a MATLAB Code to extract 14 coefficients for each species from the given data file and calculate enthalpy, entropy and specific heats for all the species in the data file.   Governing Equations: The governing equations are as follows:   Cp = Specific Heat of the specimen (J/kg K). H = Enthalpy of the…

Aim: Write a code in MATLAB to optimize the stalagmite function and find the global maxima of the function. Genetic Algorithm: The main goal of using a Genetic Algorithm is to find minimum values of the function. Genetic Algorithms are widely used in mathematical optimizations. GA’s are a search based algorithms…

Aim: Write a MATLAB Code to fit a linear and cubic polynomial for the given Specific heat (Cp) data. Also, write a MATLAB Code to show split-wise method.   Curve Fitting: Curve fitting is a process of constructing a curve that has a best fit to a series of data points, possibly subject to constraints. Curve fitting…

Aim: Write a MATLAB Program to solve the given Ordinary Differential Equation. The equation describes the position of the pendulum ball with respect to time. `(d^2 θ)/dt^2 +b/m (dθ)/dt+g/L sinθ=0` Governing Equation: The given equation is a 2nd Differential Equation. In the given equation, b= damping…

Aim: The aim of the project is to write a MATLAB program for an Otto Cycle, plot the PV diagrams and compute the thermal efficiency of the cycle. Otto Cycle: Otto Cycle is the ideal thermodynamic cycle that describes the basic functionality of the Spark-Ignition (SI) engine. The following figure shows the ideal processes…