Week 9 - Project - Master Section Development

Points Need to Be Taken Care of While Finishing the Design: The following are the points taken into consideration while finishing the design. Hole Concentricity and Hole Sizes: All part holes' concentricity and hole sizes are checked for easy assembly while finishing the parts. Machining Area: The machining area in every…

What are drawing templates?  Compared to conveying data in verbal or written form, symbols and drawing provide information in a better and more understandable way minimizing errors caused by miscommunications or misunderstandings. Drawing templates are standards decided by the client.  Drawing templates are used…

1) What do you understand by the 3D finish process?       3D finish process means to finish the design is being completely and make it ready for final simulation & 2D detailing. The following are the basic rules to be followed in 3d finishing:  The nominality of holes is to be checked which…

Week 7 - Base Unit Design 1: What is the Base Unit? What are the typical parts of the Base Unit? Base Unit:  The base unit is the unit of the fixture which is designed as such so that other units of the fixture can be mounted on it. Apart from these units, other necessary tools like a pneumatic valve box and trunking…

1. What is Design Methodology? Design Methodology is a sequence of steps that we have to follow while doing design. The above image is of the design methodology and steps involve in it. Purchase Order:  We start designing after the customer gives us a purchase order. So, basically, it is an indication to…

Design of Base Unit:   A base unit is designed to mount all other units(Clamp unit, pin unit, rest unit, etc) of the tool. Other parts necessary for a tool like a Pneumatic valve box, and trunking cable path will also be mounted onto a base unit. And below are some parts of a base unit in general.   A base plate…

Week - 6 Clamp Unit Design Parts that are required for Swivel Clamp Unit are: Clamp Cylinder: Configurations of the clamp cylinder are: CKG1: Series of cylinder B: Clevis width as 19.5 mm. 63: Bore size 100: Stroke of cylinder Clamp Arm: The clamp arm should be designed considering the stroke length…

Project: WEEK-5 Clamp and Rest unit design Aim : The motive of this project is to develop a clamp and rest unit for the given part using Mylars, Clamp Arm, Pneumatic Cylinder, L bocks, and Riser. Bought out Parts used: Pneumatic cylinder and Clamp Arm Assembly. The opening angle of the clamp arm changes from product to…

Week 4 - Pin Unit Design  Considerations for Pin design: The pin should engage about 3-5mm above the surface of BIW. All Pin units should have 2 adjusting shims. A cut for restricting the rotation of the pin. Threaded hole at the bottom for mounting with retainer block. Pin Design: Similarly, all four pins were designed.…

1. 2. Types of joining process: Metallurgical Joining Mechanical Joining Types of welding: Welding processes can be broadlyclassified into (i) fusion welding, and (ii) solid-state welding Fusion welding:In fusion-welding processes, heat is applied to melt the base metals. In many fusion welding processes, a filler…

1. Body in White (BIW), is a grey sheet metal body, joined together as a structure by various joining techniques such as welding, riveting, clinching, bonding, laser brazing, etc. Parts of a BIW:   Body side (Bodyside inner and Outer) Underbody (Front and Rear end underframe, Main floor) Closures (Front door, Rear…

Engine Wiring Harness - Project I   Study the CAD model of the engine for selecting connectors, Clips & Clamps, and Guiding channels. P clamps and Guiding channels were used for better routing of bundles. Add suitable connectors of required numbers and place them at their positions. Make sure all the connectors,…

Open the Geometric Bundle created before. Then, create a new product file and get into the electrical harness flattening workbench. Define the flattening parameters and use the extract option to bring the geometric bundle into the flattening workbench. Then, use the flattening option and select a face by which we need…

Import all the CAD models of an electrical connector and define their electrical properties like connector and bundle connection points. Bring all the necessary CAD models into the product and move them into desired locations. and define the product as a geometric bundle in the harness assembly workbench.   Create…

Week 4 Challenge   The first step is to import the CAD model of all the components used in the wiring harness. And then define their electrical properties like bundle connection and Connector connection points. I have used a sketch to define the locations of the components used. Bring all the components into the assembly…

P Clamp:  For any clamp, there can be two entry and exit points.  Import the CAD model of the support in the part design workbench. For defining those entry points, we need to create two entry and exit points and planes and a base reference plane in the mechanical part design workbench. Moving into the electrical…

Procedure For defining connectors: 1. Import the CAD Model into the part design workbench in Catia V5. 2. Create a point in the middle of the bundle and connector sides. 3.  Create an Axis system in the Connector side with y Axis projecting normal towards the connection face. 4. Now Switch to the Electrical part design…

                                                                  Project - 2                                               Mold Design for CPU Fan Bezel     1. Creation of Tooling Direction and do Draft Analysis on the part. The tooling axis for this part is taken normally to the top face. Then, draft analysis is done…

Week 12 Challenge Ejector Pins and Plate: Cooling Channels: Runner and Gate System:  

Week - 9 Challenge - Design of Sliders and Inserts for CPU fan Case    As we can see, there are undercuts in the model shown below and these undercuts cannot be cleared only with the core and cavity. Sliders are needed to remove these regions. The Need for Inserts: In the above image, the depth of cut compared…

Mold Design for Table Fan Base   1. The first step is to look for tooling direction, do draft analysis along tooling direction, and look for undercuts so that we decide where to use sliders. As these undercuts in the hole cannot be cleared along the tooling direction, we need sliders on both sides. And the draft on…

Design of Sliders - Car Door Bezel As there are undercuts in the model, and these undercut regions cannot be made only with core and cavity blocks, it needs an extra block called a slider. This slider slides in and out while opening and closing the mold using a cam. This slider also needs a holding and locking mechanism.…

                                                                                    Section Modulus of Hood Design…

                                                               Design of Backdoor using NX 12 Aim : The motive of this project is to design the backdoor inner panel, hinge, gas stay, wiper motor, and striker reinforcements from the styling surface received. And to check the manufacturing feasibility by doing a draft analysis.…

                                           Design of Roof and its Reinforcements The roof is the topmost assembly in the vehicle which not only gives a Styling look to the vehicle also has some safety considerations…

Front Fender sheet metal part that covers the engine room from sand, stones, and dust picked by tires while driving. It also gives an aesthetic look and character to the car and styling lines are used in the fender. The baffle is the plastic part attached to the fender and engine room. Fenders are mounted by fasteners…

The fender is the closure component that covers the engine, also avoids throwing dust, sand from the wheel. There are standards defined across countries on the design of wheel arc, these changes from region to region based on the road conditions, safety norms on pedestrians. Considering European standards: The wheel arc…

Hood Design and Assembly Hood assembly covers the front area of the vehicle and gives access to the engine and other parts of the car while opening. Hood Assembly consists of: Hood outer panel Hood inner panel Hinge Assembly Striker Hood inner panel consists of embosses and mastic points, location for attachment of striker…

  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. The main purpose of undercoating is to check rust especially in the body components like frame rails along with other exposed metal parts. Underbody coating…

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1. CV Joint Assembly: The first step is to create parts from the drawing using boolean operations. Then assemble these parts in the assembly workbench by adding suitable constraints with the help of references created.   2D Drafting:   2. Quick Return Mechanism: The first step is to create parts from the drawing…

1. Creation of Tooling Axis: Draft Analysis on Class A surface: Flange Creation: Class B Creation: Class C Surface: Final Trim: Draft Analysis on the final component: B Side Features: Final component with features: Draft Analysis: Draft Analysis on the final body: Model Tree:

1. Creation of Tooling axis: On extracting a surface, and creating a point at zero location and a line normal to the surface is created as a tooling axis. 2. Draft Analysis on a Class A Surface: 3. Creating Class B Surface : The Class B Surface can be created by extracting the surfaces separately, untrimmed them, and making…

1. Creation of Dog house: The dog house is a supporting feature for screw bosses to avoid sick marks in components also to get enough height for screw bosses for mating it with other components. Design rules for doghouse design: Doghouse wall thickness at the intersection of the part wall should be 40% or less than…

AS PER THE DESIGN RULES FOR RIBS IN PLASTIC DESIGN: THE WALL THICKNESS OF THE PRODUCT IS 2.5MM, SO THE THICKNESS OF THE RIB IS 0.4 x 2.5 = 1MM THE HEIGHT OF THE RIB SHOULD BE LESS THAN 5 TIMES THE THICKNESS WHICH IS HEIGHT SHOULD BE LESS THAN 12.5MM THE MINIMUM THICKNESS AT THE TOP IS 0.75MM THE DISTANCE BETWEEN THE CONSECUTIVE…

1. Creation of core body. First, we define which side core comes from. This can be judged with help of projection and depression in the component. the side which has projection will be used core and other as a cavity. parting surface for the core can be created by Trimming class A and class C surfaces with class B as shown.…

 The first step is to check whether the boundary is closed or not. This can be done using the boundary option. The closed body is highlighted by a green line. The next thing is to figure out the tooling axis for the core and cavity to move. I decide on y as my tooling axis.  Then with the help of the Bottom surface…

I. The first step is to check whether the boundary is closed or not. This can be done using the boundary option. The closed body is highlighted by a green line. The next thing is to figure out the tooling axis for the core and cavity to move. I decide on z as my tooling axis.  Then with the help of Bottom surface center,…

I. The first step is to check whether the boundary is closed or not. This can be done using the boundary option. The closed body is highlighted by a green line. The next thing is to figure out the tooling axis for the core and cavity to move. The holes that are on the top are the problem in deciding the tooling axis along…

 Feature Draft analysis of a Fan Cover I. The first step is to check the connectivity of class A surfaces. And There is no disconnectivity here.  II. Moving forward we need to check and decide the right pulling direction. Considering X and Y-Axis as pulling directions, the mold needs a side core but for…

1. Radar Mast   Design and Assembly of Yacht using SOLIDWORKS Objective: The objective of this project is to design and assemble the Yacht using SOLIDWORKS.  Introduction: The yacht is a cosmetic model where the main structures are designed by setting up the blueprint of the yacht. The structures are hull, superstructure,…

                                                   Designing of American Chopper using Solidworks Objective:  The objective of this project is to design and render a photorealistic cosmetic…

                                                   Designing of American Chopper using Solidworks Objective:  The objective of this project is to design and render a photorealistic cosmetic…