Masters in BIW Fixture Design & Plastic Design

Rs 130,000

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About this program

The Masters in Automobile BIW Design is a 12 month long, intensive program. The program comprises of 5 courses that train you on all the essential engineering concepts and tools that are essential to get into top OEMs. as a BIW Design Engineer.

Courses:

  • Advanced Sheet Metal Design
  • Automotive Sheet Metal Design using NX CAD
  • Automotive BIW Fixture Design
  • Moldflow and Polyflow Simulations for Injection Molding
  • Plastic Design Using Catia V5

Certificate

Top 5% of the class will get a merit certificate. Course completion certificate will be provided to all students who complete the course. You will receive both e-verified and hard copy of your certificates.

1. Advanced Sheet Metal Design

Week 1 - Course introduction

The Sheet Metal application provides an environment for the design of sheet metal parts used in machinery, enclosures, brackets, and other parts normally manufactured with a brake press.

NX sheet metal design software incorporates material and process information in sheet metal-specific modelling features: bends, flanges, tabs, cutouts, beads, dimples, louvers, corner and edge treatments, patterns, and other formable features.

You can also quickly convert solid models to sheet metal components, and create sheet metal parts that enclose other components.

Week 2 - Tabs

Tabs are flat profiles on a sheet metal part that serve as either the base feature or an extension of an existing flange, known as a secondary tab.

This command creates a base feature by extruding a sketch along a vector by a thickness value or adds material to a plane face.

    Week 3 - Flanges

    Adds a flange to an angle to a planar face and adds a bend between the two.

      Week 4 -
      Contour and Lofted Flanges

      Creates a base feature by extruding a sketch along a vector, or adds material by sweeping a sketch along an edge or chain of edges.

        Week 5 - Corners

        Break Corner:

        Rounds a sharp corner.

          Closed Corner:

          Closes a corner where two adjacent flanges meet by extending the bends & flanges.

            Bend Taper

            Bend Taper removes material at an angle from the bend, band, and web, or chain of child features.

              Week 6 - Bends

              Bends modify the part by bending the material based on reference geometries.

                Week 7 - Punches

                Punch adds a sheet metal feature based on the punch tool body.

                  Week 8 - Form operations

                  In this module, you will learn the techniques of rebending and unbend.

                    Weeks 9-12 - Advanced Sheet Metal Features

                    In this module, you will put together all the concepts that you have learned so far.

                      Advanced flange

                        Joggles

                          Lightning cutouts

                                              

                            2. Automotive Sheet Metal Design using NX CAD

                            Vehicle development cycle

                            This will be an introductory session where the basics of the automobiles and types of car bodies are explained. The complete vehicle development process which will explain the stages crossed by a car before it reaches the customer. The complete 3 years of development activity will be explained.

                            Basics of Automotive Body In White

                            This will be an introductory session where the basics of the automotive BiW is taught. The basics of steel and its properties are covered in major, as steel is an important component used in the cars. Steps followed in the selection of the material is discussed. Also, the cross-functional teams are explained and the need to coordinate with them is explained with the master sections and 3D components of the parts for easy and clear understanding.

                            Design Methodology of a Hood, Fender, Roof and Side Doors


                            Out of all the BiW components, we will focus our attention on the Hood, Fender, Roof, Side and Back doors. The design procedures for all the afore-mentioned parts can be summarized as follows.

                            • Design Requirements
                            • Functional Requirements
                            • Regulations
                            • Gap and Flushness requirements
                            • Safety requirements

                            Case study - Converting - RUECKWANDTUER INNER PANEL

                            In this, we will present a real-life scenario where the effect of converting an inner panel from aluminum cast to the Steel Deep Draw part will be presented. Here is a quick summary of this case. The following design parameters were identified as critical and hence were fully described:

                            • Seal Surface Width was the same as the aluminum liftgate
                            • Tailgate outer parting was maintained the same
                            • Liftgate thickness was modified
                            • Gap and flushness were maintained

                            When you enroll in this course, you will be able to clearly understand these design parameters and the decisions that were made. In this case study, the design guidelines were set through a series of CAE simulations.

                            Design of key Mechanism - Lock and Striker

                            In this module, you will first learn the anatomy of a Locker and Striker Mechanism. In order to be a successful product development engineer, it is very important to understand in detail the development process and design requirements for even the tiniest components. In this module, we will be analyzing the locker and striker mechanism in detail.

                            Process and challenges with supplier manufactured parts

                            In this module, we will look at two case studies. Both of these studies focus on supplier manufacturing practices. We will discuss the design challenges faced by two Asian Automotive suppliers and then go over the solution methodologies

                            Projects

                            Hood Design:

                            • In this particular project you will be working on to design the inner panel of a hood, according to euro cap standards and make sure that the part is manufacturer.
                            • You will provide all the necessary reinforcements at the necessary regions and join the outer and inner panel using the proper joining methods.
                            • You will also make sure that all the manufacturing requirements are being satisfied for all the cad part that you design.

                            Fender Drip area Design:

                            • In this particular project you will be working on to design the drip area for the given fender, where you will make sure to follow certain dimensions that are required to be followed for the drip area.
                            • In addition to that you will also provide the necessary bead and other embosses to strengthen the component.
                            • you will make sure that the output part meets all the tolerances to be satisfied for the deep drawing process.

                            Roof Design:

                            • In this particular challenge you will develop the ditch area and roof reinforcements.
                            • You will also be doing calculations to see if the roof passes the snow load criteria and heat distortion criteria.
                            • The number of bow roof rails will also be calculated from the above calculation.

                            3. Automotive BIW Fixture Design 

                            Introduction to BIW-Fixture

                            • Definition of BIW, Jigs & Fixture
                            • BIW-Nomenclature
                            • Types of Fixtures & their applications
                            • BIW Stations & their uses
                            • Basic terminologies

                             BIW-Fixture Basics

                            • Project Activities
                            • Different Welding Processes
                            • 3-2-1 Principle
                            • Body Planes

                            Pre-Design Processes

                            • Design Methodology
                            • Structuring a design tree
                            • Different types of fixture units

                            Units Design-1

                            • Different types Pin Unit Design
                            • Different types of Clamp Unit Design
                            • Different types of rest unit design

                            Units Design-2

                            • Dump Unit Design
                            • Slide Unit Design
                            • Base Unit Design

                            Finishing the design

                            • 3D-Finish
                            • Rough Locators
                            • Pneumatic routing
                            • Valve Banks & Selection
                            • Gun Study
                            • Sensors & selection

                            2D-Detailing Baiscs

                            • Drawing Templates
                            • Angles of projection
                            • Basic GD&T used in Fixturing
                            • Scaling & Views
                            • Various Detailing Patterns

                            2D-Detailing 1

                            • Key Sheet detailing
                            • Unit detailing
                            • Child Parts detailing

                            2D-Detailing 2

                            • Child Parts detailing continued
                            • Material Selections
                            • BOM preperation

                            Documentations

                            • Design Terminologies
                            • Sequence sheets
                            • Clamp Validations sheets
                            • Ergo-Sheets
                            • Poka-yoke
                            • Fixture Process sheet
                            • Cycle time study

                            Projects

                              1. Designing a Robot welding Fixture

                              2. Designing a Manual Welding Fixture

                              4. Moldflow and Polyflow Simulations for Injection Molding

                              Operation of Moldflow/Inputs and Outputs of the tool

                              It deals with the working of Moldflow software & amp; the inputs required for running the analysis. Types of analysis that can be executed for validating the Mold tool and for product development. 

                                Creation of Nodes and curves tools associated with its creation

                                Designing in Moldflow (i.e.) how to create a node and various options used in the creation of nodes and in the same way line creation and surface creations are explained during this session.

                                Creation of mesh/Mesh correction tools

                                Mesh is the main requirement for running the analysis. The part is segmented into small triangles and that is called as mesh Creation of mesh and mesh correction tools are explained during this session.

                                  Types of Meshing and its parameter

                                  Different types of meshes are used, depending upon the part geometry. How to create the other meshes and parameters that should be taken are explained.

                                    Gate location, Fill, Flow and Warp

                                    The module used for analyzing the part, that is, selecting the analysis depending upon the objective or requirement will be explained in this session. 

                                    How to set the process settings

                                    For executing an analysis process setting plays the main role. The results vary because of this setting. This setting is also the input for the molding machine. An idea for the process setting is explained in this session.

                                      Result analysis for fill and flow

                                      The output obtained infill and flow analysis are explained in detail during this session.

                                        Cooling circuit design

                                        The cooling circuit plays the main role in maintaining the temperature inside the mold. Many features are there in the cooling circuit and how to design that design features are explained in this session. 

                                        How to setup cool analysis

                                        For cooling analysis, different types of coolant and modifications are required to optimize the mold tool. All the settings details will be explained.

                                          Transient Cooling analysis 

                                          This is an advanced type of cooling analysis where the molding tool is also analyzed. The setup for this analysis is explained. 

                                          Analyzing the results

                                          The result obtained with different types of analysis is discussed here. The result interpretation and the basic solutions are discussed here.

                                            Result interpretations

                                            The result obtained with different types of analysis is discussed here. The result interpretation and the basic solutions are discussed here.

                                              5. Plastic Design using CATIA V5

                                              Basics of Plastic Design

                                              It includes Basic plastic terminology, the Injection molding process, design guidelines of various features, Plastic defects and how to eliminate those during the design phase

                                                Part Design Workbench (Basics)

                                                Covers basic toolbars in Part design workbench Sketches, Sketch-based features and Surface-based features, Transformation features. Surface-based features, Boolean Operations, Creating plastic part features, Navigation toolbars, and measurement tools.

                                                  Part Design Workbench (Basics)

                                                  Surface-based features, Boolean Operations, Creating plastic part features, Navigation toolbars, and measurement tools.

                                                    Surface Design Workbench

                                                    GSD Wireframe for creating a skeleton for the surfaces, GSD surfaces for new surface creation, GSD operations to modify the created surfaces. Advanced surface creation including sweep and multi-section surfaces, Surface continuity behaviors.  

                                                    Creating Power Copy

                                                    Introduction to Power Copy creation from Part design workbench, instantiating power copy in the real-time plastic model. 

                                                      Adding Thickness to Styling Surface

                                                      Creating volumes from surfaces, How to create B side surface from the aesthetic surface, Creating closed volume checking draft analysis.

                                                        B Side Features Creation

                                                        Adding attachment and strengthening features, Creating plastic part features like Rib, Boss, Gusset, Dog House using part design.

                                                          Draft Analysis in Detail

                                                          Tooling analysis of plastic parts, finding out tooling direction of a part, eliminating undercut areas for easy manufacturability.  

                                                          Complete Model Creation from Styling Surface

                                                          Creating volumes from A – Surface, reading master sections, adding B side features including locators, ribs, analyzing tooling feasibility issues.                  

                                                              FAQ

                                                              1 . How will the instructor teach?

                                                              Our instructors are industrial experts working in Fortune 500 companies. We partner with them to deliver the lectures online. You will be given access to recorded content and assignments each week.

                                                              2 . Are there any prerequisites for this course?

                                                              You should be pursuing B.E/B.Tech in Mechanical, Aerospace, Automotive, Production or Manufacturing

                                                              3. What kind of support I can expect?

                                                              Our support system is amazing!. You can read our reviews on Google to see this. We focus on one-on-one support which no one else does. We will communicate with you through WhatsApp messages/calls, individual online sessions and also in person.

                                                              4 . How can I use the letter of recommendation?

                                                              You can use it for job search and higher education. Recommendation letters are given only for candidates that have performed extremely well.

                                                              Understand more about our Job Guarantee or Money back program.

                                                              Appointment details will be emailed to you. Check promotions folder

                                                              Modes of Support

                                                              We offer 6 modes of support through which you can contact the instructor and the support engineers to clear your doubts & questions.

                                                              Live Support Sessions

                                                              Every week, there will be 3 support sessions where you can interact one-on-one with the instructor to clear your doubts.

                                                              WhatsApp Groups

                                                              You will be in a WhatsApp Group along with the course instructor & support engineers where you can post your questions.

                                                              Forum Pages

                                                              We have a very vibrant course forum where you can find the answers to most of your doubts.

                                                              Ticketing Systems

                                                              You can also send us your questions through the mail where a ticket will be created and your questions will be answered shortly within a few hours.

                                                              On-Call Support 

                                                              In case, you want to clear any doubts immediately, you can always call our support engineers & they will be happy to assist you,

                                                              Online Chat Support

                                                              You can connect to us anytime with our all-time chat support. You can explain your doubts. We will help you right away through call or live session.

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