Injection Molding and Injection Mold Nomenclature: PART 2

OBJECTIVE: The primary objective of this project is to design and model individual components of a butterfly valve using the provided drawings while applying Geometric Dimensioning and Tolerancing (GD&T) principles to each component within the Siemens NX CAD environment. Upon successfully creating the individual…

OBJECTIVE: This project aims to demonstrate the practical application of wiring harness routing and design principles on a car's backdoor/tailgate using CATIA V5 software. The main objective is to showcase the implementation of industry best practices and packaging rules studied throughout the course by creating a properly…

OBJECTIVE STATEMENT: The primary objective of this assignment is to design and route a comprehensive wiring harness for a given engine using CATIA V5 software. The design process will encompass applying industry-standard packaging rules, best practices, and guidelines acquired through the coursework. Particular emphasis…

OBJECTIVE: Take the harness assembly from the previously completed challenge and flatten it. Position this flattened view on the drawing sheet. It’s important to make sure that bundles with protective coverings are visually distinct in the drawing view. This step is part of our ongoing process to create a drawing…

OBJECTIVE: To utilize the Electrical Part Workbench tools in CATIA V5 to define and assign the required electrical properties for connectors and connector clips obtained from Tyco Electronics or TE Connectivity's website CAD files.    INTRODUCTION: ELECTRICAL DISTRIBUTION SYSTEM(EDS): The Electrical Distribution…

OBJECTIVE STATEMENT: The objective of this project is to design and develop a fully routed and annotated automotive wiring harness assembly in .igs format, using the following steps:   Route the harness layout in the Electrical workbench using the provided connectors. Check the bundle continuity and provide a snapshot…

OBJECTIVE: To route the wiring harness using the specified layout diagram, defining and incorporating electrical connectors downloaded from www.te.com, and accurately positioning them in the Electrical Harness Assembly Workbench for seamless integration. After these connectors are routed accordingly we have to apply…

WIRING HARNESS ROUTING AND PACKAGING RULES   OBJECTIVE: The objective of this project is to analyze and comprehend various models of clips, backshells, and corrugated tubes, and transform the provided CAD data file of the P clamp into an electrical support component. Additionally, the back shell will be converted…

The objective of this report is to detail the design process of creating the backdoor of a car using Class A Surfaces in NX CAD. The report will cover the steps involved in developing the upper and lower panels, creating the inner panel and various mountings, and incorporating reinforcements and embosses for stiffness and impact resistance. It will also discuss the use of cutouts for weight reduction and the implementation of the hemming process. The aim is to provide a comprehensive overview of the design decisions and techniques used, ensuring adherence to design specifications and industry standards.

OBJECTIVE:  To create the Door Trim Lower Plastic Component through the given Class-A Surface and then create the Heat Stakes and the Locators considering the design rules for the Door Applique.      REFERENCE IMAGE:   MAIN REPORT: Types of Surfaces and their importance for an Automotive Plastic…

OBJECTIVE: This report aims to document the design and development process of a Door Trim panel, adhering to industry standards and best practices. The objective is to create a CAD model with a thickened part, mounting features, and attachment strategy, including Push pins with Doghouse and heat stakes, while considering material details, draft analysis, tooling analysis, and parting lines to ensure efficient and smooth production. The output will serve as a valuable reference for future production and maintenance of the Door Trim panel.

OBJECTIVE: This report aims to design and assemble a hood for the specified project, incorporating various components such as the outer panel, inner panel, reinforcements, latch, and hinge. It will provide detailed explanations of each component's role, latch trajectory analysis, mastic data integration for sealing purposes, emboss definitions for aesthetics considerations. The manufacturing processes of deep-drawing and hemming techniques will be outlined with relevant parameters. The report will follow a well-formatted structure and include relevant images to enhance understanding.

The objective of this project is to design the front fender of a car using NX CAD software, incorporating various mounting features such as Drip Area Mounting, Sill Mounting, Bumper Mounting, A-Pillar Mounting, and Baffle Mounting. Utilizing the provided initial surface and Master section for the Drip Area Mounting creation as a reference point, the aim is to develop a robust and efficient design that aligns with engineering standards learned during academic studies.

OBJECTIVE: This report analyzes and designs the outer roof structure of a car, using a Class A Surface. The focus is on creating a comprehensive outer roof assembly with required reinforcements in the form of five bow roofs. These reinforcements aim to enhance structural integrity under varying loading conditions. Pre-defined Master Sections are utilized for each bow roof to ensure compatibility and uniformity within the design. Thorough calculations regarding Heat Distortion and Snow Load Criteria will be conducted to meet industry standards for thermal stability and load-bearing capacity. Special attention will be given to integrating an additional reinforcement roof when incorporating a sunroof into the assembly.

OBJECTIVE: The objective of this report is to evaluate and compare four vehicles within the budget range of 8 to 10 lakhs on-road, taking into consideration the specific requirements of Mr D.S. Pughazhyendhii, who resides in the crowded city of Bangalore. The report aims to provide recommendations for a suitable car that…

OBJECTIVE: To analyze the section modulus of the existing hood design and propose a modified section that exhibits an improved section modulus, thereby enhancing the structural strength and rigidity of the hood. Calculate the Section Modulus: Utilize the given formula `S = I/Y` to determine the section modulus…

OBJECTIVE: The objective of this report is to provide a comprehensive overview of underbody coating for automotive applications. The report will examine the purpose of underbody coating, explore different types of coatings in detail, and analyze their respective advantages and disadvantages. By the end of the report, readers…

OBJECTIVE: To assess the wheel arch alignment of the fender and determine if it meets the European standard by calculating the Wheel Arch gap at specified points. The objective is to verify that: Verify that there is a 10mm offset, ensuring that the wheel remains inside the fender's outermost surface. Measure and…

OBJECTIVE: To create the Door Handle Plastic Component from the given Class A Surface & then create attachment features such as Ribs and Screw Bosses for it while following the issued Design Guidelines.    KEYSHOT RENDERING OF THE FINAL FILE:   Use case of Rib in any Plastic Component: Ribs…

OBJECTIVE: This report aims to document the process of creating two assemblies, including the creation of individual part files and assembly workbench, using 2D diagrams. Additionally, this report will detail the use of drafting tools to create 2D drawings of those particular parts and assembled bodies as well.…

OBJECTIVE: Create the Solid CATparts from the 2D drawings using the Boolean Operation (Add, Remove, and Union Trim).   KEYSHOT RENDERING OF FINAL FILES:       1. DRAWING ONE:         GEO-SET TREE STRUCTURE(IT IS EXPANDED FOR EACH PART INDIVIDUALLY LATER IN…

OBJECTIVE: To create the Door Trim Plastic Component from the given Class A Surface & then create two dog houses as attachment features for it while following the issued Design Guidelines.   KEYSHOT RENDERINGS OF THE FINAL FILES:   Use case of Dog-House in any Plastic Component: The…

OBJECTIVE: To create the Base-Bracket's Plastic Component using the Class A Surface that is provided. Firstly, we have to create the required Tooling-Axis for the given Class A Surface while meeting the requirements of the necessary Draft Angle & then perform the Draft-Analysis Operation on the…

OBJECTIVE: To create the Switch Bezel's Plastic component using the Class A Surface that is provided. Firstly, we have to create the required Tooling-Axis for the given Class A Surface while meeting the requirements of the necessary Draft Angle & then perform the Draft-Analysis Operation…

OBJECTIVE: To create the Coin Holder's Plastic component using the Class A Surface that is provided. Firstly, we have to create the required Tooling-Axis for the given Class A Surface while meeting the requirements of the necessary Draft Angle & then perform the Draft-Analysis Operation…

OBJECTIVE: To create the Bumper's Plastic-Component using the Class A Surface that is provided. Desired Thickness of the Plastic Component is 3mm with 3 degrees as the Draft Angle.   Firstly, we have to create the required Tooling-Axis for the given Class A Surface while meeting…

OBJECTIVE: To create the Door Trim Lower's Plastic Component using the Class A Surface that is provided. Desired Thickness of the Plastic Component is 2.5mm with 3.2 degrees as the Draft Angle. Firstly, we have to create the required Tooling-Axis for…

OBJECTIVE: To create the Core & Cavity blocks for the Switch Bezel designed in the earlier challenge.    Guidelines for the Tree Structure: Ensure Proper Tree Structure. Geometrical sets should have a proper name based on the sketches present inside of them. All the sketches should be created under the…

OBJECTIVE: To create the A-Pillar's Plastic component from the given Class A Surface using the Master Section that is provided while following all the design rules.     INTRODUCTION: Types of Pillars and their Importance in the Automotive Industry:-   These pillars standing at the vertical…

OBJECTIVE: To create the 2D Drafting-Sheet with Title Block and Frame from the Solid CATpart created using Boolean Operation. DRAWING ONE:- 2D MODEL IN VARIOUS ORIENTATIONS:  1. FRONT VIEW: 2. TOP VIEW:   3. SECTION VIEW:    4. ISOMETRIC VIEW:   FRAME AND…

PART-WORKBENCH OBJECTIVE: To create the Solid CATparts from the 2D-Drawings.  1. DRAWING ONE:             GEO-SET TREE STRUCTURE(IT IS EXPANDED FOR EACH PART INDIVIDUALLY LATER IN THE REPORT):    SKETCHER WORKBENCH: 1. SKETCH FOR MAIN SECTION:   2. SKETCH…

SKETCHER WORKBENCH OBJECTIVE: To create 2D Sketches in CATIA while following the necessary guidelines.    MAIN REPORT:  1. DRAWING ONE: SKETCH'S IDEA:    PART MADE IN CATIA:    VIEW  OUTSIDE THE "Sketch Mode":   TREE STRUCTURE WITH GEOMETRICAL SETS AND CONSTRAINTS: …

OBJECTIVES: 1. DEFINE WHAT IS FVM(FINITE VOLUME METHOD).  2. DIFFERENTIATE BETWEEN FDM AND FVM.  3. DESCRIBE THE NEED FOR INTERPOLATION SCHEMES & FLUX LIMITERS IN FVM.    THEORY:   We know that in Fluid Dynamics there are three numerical-method based solvers which are used to solve for…

OBJECTIVE: Write a program to solve the ODE provided below of the equation of motion for a simple pendulum and to simulate its transient behavior. Also, create an animation of its motion.    `(d^2theta)/(dt^2) + b/m*(d theta)/(dt)+g/L*sintheta = 0` In the above equation, g = gravity in m/s2, L = length of the…

AIM: USING DATA ANALYSIS TECHNIQUES, PERFORM VALIDITY AND COMPATIBILITY CHECK FOR AN ENGINE DATA FILE, VISUALIZE THE DATA USING PLOTTING COMMANDS AND EVALUATE SOME BASIC PERFORMANCE DETAILS USING PYTHON.   OBJECTIVE:  1. DATA VISUALIZER Script should take column numbers as the input and plot the respective…

OBJECTIVE: BREAKING ICE USING THE NEWTON RAPHSON METHOD ON AN AIR CUSHION VEHICLE BY CALCULATING THE MINIMUM PRESSURE REQUIRED TO BREAK THE ICY SURFACE.    THEORY:  AIR CUSHION VEHICLE: Recent experiments, using air cushion vehicles have demonstrated that they can be used successfully to break up ice…

OBJECTIVE: COMPARE THE CONVERGENCE RATE [NUMBER OF ITERATIONS] OF THE STEADY-STATE AND TRANSIENT-STATE [EXPLICIT AND IMPLICIT] SIMULATIONS AND JUSTIFY THE NUMERICS.   THEORY FOR STEADY AND TRANSIENT-STATE HEAT TRANSFER:   Heat transfer is described as the flow of heat due to temperature differences and the…

OBJECTIVE: In this challenge, you are going to simulate the isentropic flow through a quasi 1D subsonic-supersonic nozzle. You will derive both the conservation and non-conservation forms of the governing equations and solve them using MacCormack's technique. You need to determine the steady-state temperature distribution…

OBJECTIVE: In this challenge, you are going to simulate the isentropic flow through a quasi 1D subsonic-supersonic nozzle. You will derive both the conservation and non-conservation forms of the governing equations and solve them using MacCormack's technique. You need to determine the steady-state temperature distribution…

SIMULATION OF A BACKWARD-FACING-STEP IN OpenFOAM   AIM: Simulate an incompressible-laminar-viscious flow through the backward facing step geometry. Perform transient simulation; choose the solver based on the described physics of flow in problem statement.  Explain simulation process and way of setting up the…

REPORT 2 OBJECTIVE: TO PROVIDE AN OVERVIEW OF THE MATERIAL SELECTION PROCESS, IDENTIFYING AND UNDERSTANDING THE CHARACTERISTICS OF VARIOUS KINDS OF PLASTICS USED IN THE AUTOMOTIVE INDUSTRY, UNDERSTANDING VARIOUS AUTOMOTIVE COMPONENTS AND MANUFACTURING PROCESSES.    MAIN REPORT:  1. FACTORS TO BE CONSIDERED…

REPROT 1 OBJECTIVE: The main objective of this report is to provide an overview of the things a 'Product Design-Engineer' should know about the Automotive Industry and also study of the entire set of steps in the lifecycle of an Automotive Product from the 'Concept Sketching' phase to 'Mass Production' phase. …

REPORT 2 OBJECTIVE: TO STUDY INJECTION MOLDING AND INJECTION MOLD NOMENCLATURE   MAIN REPORT:  1. TYPES OF INJECTION MOLDING MACHINES:  An injection Molding Machine is a special machine designed for manufacturing mostly plastic products. Mostly. It comprises two sections that are Injection Unit & Clamping…

REPORT 1 OBJECTIVE: TO STUDY INJECTION MOLDING & INJECTION MOLD NOMENCLATURE MAIN REPORT:  1. FREEHAND SKETCH OF AN INJECTION MOLDING MACHINE:   An Injection Molding Machine has three main units consisting of several parts in each unit that are as follows: A) Injection Unit: The Feed Hopper with Hopper Dryer,…

AIM: TO PERFORM CURVE FITTING OPERATIONS USING PYTHON   OBJECTIVES: 1. EXPLAIN THE ROLE OF  'popt' &'pcov' IN THE curve_fit FUNCTION.   2. EXPLAIN THE ROLE OF 'np.array(temperature)' WHICH IS BEING USED IN THE CODE.  3. EXPLAIN THE ROLE OF '*' IN *popt.  4. TO PERFORM CURVE-FITTING…