Week 9 Challenge

Aim: To Create Sliders for the Undercuts present in the CPU Fan Case. Undercuts: Any indentation or protrusion that prevents a part from being ejected from a mold is known as an undercut. It is a quality that the cavity and core by themselves are unable to capture. Because it is die-locked, the part cannot be ejected from…

Aim: To create 2 sliders for the 2 undercuts present in the modelUndercuts: Any indentation or protrusion that prevents a part from being ejected from a mold is known as an undercut. It is a quality that the cavity and core by themselves are unable to capture. Because it is die-locked, the part cannot be ejected from…

Aim: To design two different types of rest unit and three different types of power clamp units for a certain car panel in CATIA V5.   Clamp unit: A tool called a clamp unit uses NC blocks, mylars, or a rest to clamp or hold a vehicle panel while employing a pneumatic cylinder. The standard components of a clamp unit…

Base Unit and its parts A base unit is designed to house all the tool's other components, such as the clamp unit, pin unit, rest unit, etc. Other elements required for a tool, such as a pneumatic valve box and a cable route, will also be installed on a base unit. Additionally, the base unit mounts elements such as the…

Pin Unit Design AIM: Designing of the fixed pin unit and retractable pin unit for fixing of panel using CATIA software.   Theory Of Pin: Pin unit consists of Pin, Pin retainer, L Block, Shims, Blade, and Riser.  The primary function of any locator is to reference the workpiece and to ensure repeatability.  …

Q1. Design Methodology Different design methods are simply the procedures used while conceptualizing a fixture design. Design methodology is divided into four sub categories: Purchase Order. Inputs from Customer. Percentage Completion Criteria. Design Output Purchase Order: A purchase order essentially serves as the customer's…

Process of Project execution RFQ Received: This is the project's initial stage. Request for Quotation is referred to as RFQ. The client provides data or papers that describe the requirements or specifications in detail for the assigned project. Also, the customer requests a quote for the entire project and provides technical…

Body In White: The most widely used modern car structure type, is the unitary type, spot welded, pressed steel sheet metal body. It is well suited to mass production methods. The body is self-supporting, so that the separate ‘chassis’ is omitted, with a saving in weight. In the integral structure the panels…

In this project, we aim to route the wiring harness on a top opening Backdoor Class-A surface, and prepare flatten view and wiring harness drawing in CATIA V5. All types of packaging rules are considered while routing the harness. All necessary details like clearance, clips, harness continuity is considered while designing…

Backdoor Design It is a Hinged door at the rear of the vehicle that can be moved up and down to either in most cases to a storage compartment/boot or to rear seats in some cars. Sometimes also referred to as Tailgate or Boot-door. The Backdoor is an assembly of parts such as inner panel, outer panel upper, outer panel…

In this project, we aim to route the wiring harness on given V-16 Engine Class-A surface, and prepare flatten view and wiring harness drawing in CATIA V5. All types of packaging rules are considered while routing the harness. All necessary details like clearance, clips, clamps, harness channels, harness continuity is considered…

Objective- To create a flattened-view of a harness assembly and create 2D drawing on a drawing sheet. Harness assembly for which flattened-view must be created To generate a flattened view of wiring harness, we should work in the Electrical Harness Flattening workbench of CATIA V5. Defining Harness Flattening parameters…

Aim- To Route two electrical harness bundles as per the given layout and interconnect them as a single harness assembly and check for bundle continuity, bundle warnings, and give annotations to the final harness assembly. Connectors •          Define all connectors as electrical…

AIM: To Route the following harness layout in Electrical workbench. Add protective covering on all branches connected to DT06-2S & DT06-4S connectors. Keeping end extremity at 30mm (from connectors end) Flow chart of wiring and harness assembly Identifying Harness Assembly components Defining all Harness components…

Objective: To download the P-Clamp CAD data and define it as Electrical Support in the Electrical Part design workbench and define the necessary electrical properties. To download the Back-shell CAD data and define it as Electrical Back shell in the Electrical Part design workbench and define the necessary electrical properties.…

Introduction Electrical Distribution system (EDS) and Wiring harness 1) Electrical Distribution System: It involves physical and logical schematic architecture development, power distribution, design of wiring harness of given electrical system. The physical location of all electrical components placed in the vehicle can…

Roof Design The conventional task of the roof panel is that of compartment shielding and connection of body sides, front and rear roof cross members. In the case of roll over, compartment integrity is provided by the compartment frames. Any roof panel material requires braces to prevent panel flexing and vertical waviness,…

Benchmarking Benchmarking has been unanimously accepted as an effective performance and productivity improvement tool by auto companies. Benchmarking can be used effectively as a tool to compare product attributes, quality attributes, operations, and processes. Benchmarking involves a structured comparison between similar…

Underbody Coating A vehicle's underbody is subject to wear and tear caused by elements such as stones, potholes, muddy water. To prevent this from happening a coating is applied to the underside of the car body known as underbody coating. This shields the underbody from rust and the debris coming off-road. Pre-treatment…

Section modulus Section Modulus is a geometric property used to calculate the bending stresses in a structural member. It is defined as the ratio of the moment of inertia of a section about its centroidal axis and the distance of the extreme layer from the neutral axis. Section modulus, S = I/y                    …

Fender Design Fender is a closure component, closing the engine compartment from the left and right side of a car. During the motion of the automobile, the wheel picks up a sand, mud and small particles and throws it inside the car and fenders will be helpful in preventing them. Two types are Fenders are designed, Full…

Fender Wheel Arch Calculation Wheel Arch is the semi-circular part of the fender located above the wheel of the vehicle. The wheel arch area of the fender is usually designed as cover over the tyre to stop any stones or debris, dirt, and sand from getting thrown into the vehicle. Different regions have different wheel…

Hood design The hood is a hinged cover that encloses the engine in a front engine vehicle whereas it acts as a door for the front trunk in a rear engine vehicle. Hood opens to allow access to engine compartment. Hood is an important component of a vehicle considering the frontal crash and pedestrian safety requirement.…

                                              Final project - Door Trim Panel Door panels serve as an interface between the interior of the car and the inner components of the door. They are designed in such…

Creation of Tooling Axis 1. Since the part has a compliacted geometry, we will use Measure Inertia method to find the tooling Axis. 2. Click on the Measure Inertia option and choose the Class A surface. 3. Under the create geometry option, Choose non assosiative geometry and choose center of gravity.  4. The center of…

Tooling Axis Creation 1. Extract a flat surface from the Door Trim. Create a point on the center of the extracted surface. Draw a normal line to the surface. This line is taken as the tooling axis for the Door Trim. Here it is convinient for us to create a tooling axis directly rather than following the bisecting method.…

Tool axis Creation 1. Extract a surface as reference and create a point on the center of the extracted surface. 2. Inorder to clear tooling path along Y direction, Use Project 3D elements command on XY plane with the Class A surface. Consider the outer walls and extend the lines. 3. Create a bisecting line by choosing…

Tooling Axis Creation 1. Extract a flat surface from the bumper. Create a point on the center of the extracted surface. Draw a normal line to the surface. This line is taken as the tooling axis for the bumper. Here it is convinient for us to create a tooling axis directly rather than following the bisecting method. Draft…

Tool axis creation procedure 1. Create a point and an axis system by extracting the base surface of the Switch Bezel and taking it as the reference.  2. Inorder to clear tooling path along Y direction, Create a sketch with YZ plane and a point drawn on the extracted surface of the base as reference. Use Intersect…

Tool axis creation procedure 1. Create a point and an axis system at the center of the hole. The hole is considered center since it lies at the center of the part and the part being symmetric. 2. Inorder to clear tooling path along Z direction, Use Intersect command on YZ plane with the Class A surface. Similarly if it…