Bybo909029 Apd r Amith Kumar

8/14/2019 Bybo909029 Apd r Amith Kumar

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COMPUTER AIDED ENGINEERING

ASSIGNMENT

Centre Name: A.P.D

Course Name: M.Sc. [Engg.] in Automotive ProductDesign

Name of the Student : R AMITH KUMAR

Student Registration No : BYB0909029

Module Leader at MSRSAS : HARSHALSAWANT

FULL TIME 2009 BATCH

M. S. Ramaiah School of Advanced StudiesNew BEL Road, Gnanagangothri Campus, MSR Nagar, Bangalore-560 054

Tel: 23605539 / 23601983 / 2360 4759. Fax: 2360 1923website : http://www.msrsas.org

POSTGRADUATEENGINEERINGANDMANAGEMENT

PROGRAMME(PEMP)


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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)

Declaration Sheet

Student Name R AMITH KUMAR

Reg. No BYB0909029

CourseAUTOMOTIVE PRODUCTDESIGN

Batch FT-2009

Module Code AME501

Module Title COMPUTER AIDED ENGINEERING

Module Start Date 09/11/2009 Submission Date 7/12/2009

Module Leader HARSHAL SAWANT

Submission ArrangementsThis assignment must be submitted to Academic Records Office (ARO) by the submission date before 1730hours for both Full-Time and Part-Time students.

Extension requestsExtensions can only be granted by the Head of the Department / Course Manager. Extensions granted by anyother person will not be accepted and hence the assignment will incur a penalty. A copy of the extensionapproval must be attached to the assignment submitted.

Late submission PenaltiesUnless you have submitted proof of Mitigating Circumstances or have been granted an extension, the penaltiesfor a late submission of an assignment shall be as follows: Up to one week late: Penalty of one grade (5 marks) One-Two weeks late: Penalty of two grades (10 marks) More than Two weeks late: Fail - 0% recorded (F 2)

All late assignments must be submitted to Academic Records Office (ARO). It is your responsibility toensure that the receipt of a late assignment is recorded in the ARO. If an extension was agreed, theauthorization should be submitted to ARO during the submission of assignment.

To ensure assignments are written concisely, the length should be restricted a limit indicated in theassignment questions. Each participant is required to retain a copy of the assignment in his or her record incase of any loss.

Declaration

The assignment submitted herewith is a result of my own investigations and that I have conformed to the

guidelines against plagiarism as laid out in the PEMP Student Handbook. All sections of the text and results,

which have been obtained from other sources, are fully referenced. I understand that cheating and plagiarism

constitute a breach of University regulations and will be dealt with accordingly.

Signature of Delegate

Date

Date Stamp fromARO

Signature of AROStaff

Modern Automotive Systemsii


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Signature of Module Leader

Signature of Course Manager

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M. S. Ramaiah School of Advanced StudiesPostgraduate Engineering and Management Programme- Coventry University (UK)

Assessment Sheet

Department Automotive and design engineering

Course Automotive Product Design Batch Full-Time 2009

Module Code AME501 Module Title Computer aided engineering

Module Leader Harshal sawant Module CompletionDate 5/12/2009

Student Name R Amith kumar ID Number BYB0909029

Attendance Details Theory Laboratory Fine Paid(if any for shortage of attendance)

Remarks

Written Examination Marks Sheet (Assessor to Fill)

Q. No a b c d Total Remarks

1

2

3

4

5

6

Marks Scored for 100 Marks Scored out of 50

Result PASS FAILAssignment Marks-Sheet (Assessor to Fill)

Part a b c d Total Remarks

AB

C

Marks Scored for 100 Marks Scored out of 50

Result PASS FAIL

PMAR- form completed for student feedback (Assessor has to mark) Yes NoOverall-Result

Components Assessor Reviewer

Written Examination (Max 50) Pass / Fail

Assignment (Max 50) Pass / Fail

Total Marks (Max 100) (Before Late Penalty) Grade

Total Marks (Max 100) (After Late Penalty) Grade

IMPORTANT1. The assignment and examination marks have to be rounded off to the nearest integer and entered in the respective fields2. A minimum of 40% required for a pass in both assignment and written test individually3. A student cannot fail on application of late penalty (i.e. on application of late penalty if the marks are below 40, cap at 40 marks)

Signature of Reviewer with date Signature of Module Leader with date

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AbstractChapter 1 discusses with study of digital prototyping the different areas of its application and

companies involved in it. The benefits and issues related to digital prototyping. The scenarioregarding India in the field of digital prototyping is also being discussed in the chapter.

Chapter 2 contains the work carried on the CATIA 3D modelling software. The 3D model of

fuel injector and its parts and assembly in being explained along with the respective drawings,

clash analysis and the steps involved in making it. And the functionality of fuel injector is

been briefly looked into. Chapter 3 deals with one the reverse engineering technique i.e.

sketch tracing method used to create the 3D surface model of GM pick-up truck. The chapter

the process of reverse engineering briefly and the steps involved in sketch tracing technique

used.


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Table of ContentsAbstract ....................................................................................................................................... i

Table of Contents ....................................................................................................................... ii

List of Figures ............................................................................................................................ ii

Nomenclature ....... iv

CHAPTER 1 .............................................................................................................................. 1

1.1 INTRODUCTION ............................................................................................................. 1

1.2 DIGITAL PROTOTYPING .............................................................................................. 1

CHAPTER 2 .............................................................................................................................. 4

2.1 FUEL INJECTOR ............................................................................................................. 4

.................................................................................................................................................. 15

CHAPTER 3 ............................................................................................................................. 16

CHAPTER 4 ............................................................................................................................. 24

REFERENCES ........................................................................................................................ 25

BIBILIOGRAPHY ................................................................................................................... 26

List of FiguresFig 2.1 Adjusting screw5

Fig 2.2 Body...6

Fig 2.3 Cap..7

Fig 2.4 Distance piece.8

Fig 2.5 Locknut..9

Fig 2.6Nozzle.10

Fig 2.7 Nozzle holder11

Fig 2.8 Nozzle pin...12

Fig 2.9 Screw adjuster..

13

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Fig 2.10Spring.14

Fig 2.11 Fuel injector assembly..15

Fig 3.1 Projection of all views 18

Fig 3.2 Wireframe model 19

Fig 3.3 Rendered model isometric view 20

Fig 3.4 Cutting plane analysis21

Fig 3.5 Isophotes mappinganalysis.21

Fig 3.6 Environment mapping analysis22

Fig 3.7 Final rendered model isometricview.23

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Nomenclature

Acronyms

CAD Computer aided design

CAE Computer aided engineering

CAM Computer aided manufacturing

OEM Original equipment manufacturer

CIM Computer integrated manufacturing

2D &3D 2 dimensional and 3 dimensional;HMD Head mount display

GD&T General dimensioning and tolerance

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CHAPTER 1

1.1 INTRODUCTION

In the recent years the competition for manufactured products has intensified

tremendously. It has become inevitable, for new products to reach the market as soon as

possible, before the competitors product is launched[1]. Traditionally product development

was based on design iterations & building costly and time consuming physical prototyping

(models). In order to reduce this design process, simulation based engineering like Digital or

Virtual Prototyping is being used nowadays .

1.2 DIGITAL PROTOTYPING

Digital Prototyping helps in giving a conceptual design to the engineering,

manufacturing, and sales & marketing departments the ability to virtually explore the

complete product before its built[1]. This method allows visualization of the assembly of

parts & check the feasibility of the designed assemblies and their layout within production

constrains. By using the assembly of an accurately made virtual prototype, design flaws can

be detected and respective modifications can be performed so that actual assembly can be

accomplished on the first try without any flaws.

It basically involves digital simulation and testing for validating and verifying designs

and related processes, and is an intensely mathematic-based method of viewing them.

Some of the tools and technologies available which is used in digital prototyping:

Photo-real images and Animations: - Used for creating photorealistic renderings and

animations of products prior to manufacturing.

3D CAD: - Surfacing and solid-modelling allows fully detail the design before

producing any physical samples.

Simulation Tools: - Perform integrated calculations, and stress, deflection, and

motion simulations to validate designs.

3D CAE: - Tools to analyse verify and validate designs.

Rapid Prototyping: - It enable to look / feel / fitment assessments of new product

designs without the expense of tooling and production setup.


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Some of the companies that have product or service relate to Digital Prototyping are

Autodesk, Dassault Systems, Siemens PLM Software, PTC, and Rhinoceros. Providing

softwares like Autodesk Alias Automotive, Catia, Pro/ENGINEER, Siemens Team enter,

Rhinoceros, Autodesk 3ds Max etc. for different Digital Prototyping applications.

1.3 ADVANTAGES WITH DIGITAL PROTOTYPING:

.There is a control over Form, Fit & Function well ahead of production hence savings

on investment to be made on this process.

Reduced Interpretations that occur with 2-dimensional drawings which were earlier

used for the production of parts.

One of the greatest benefits of using math-based methods is that we can actually seecause-and-effect and track things we cant physically measure

We can study and explore the function, ergonomics and aesthetic feature. Thus

alternatives can be designed without spending time and Money on producing physical

samples and variations of the product concept .

1.4 Industry application cases of virtual engineering :

Stockholms Metrocar 2000[2]Metrocar 2000 is Stockholms new public transportation system designed by Adtranz

Sweden. Using divisions dVISE software. Adtranz demonstrated virtual prototypes of the

trains that include fully furnished interiors with texture mapped seats, floor, advertisements

and driver display panels. Looking at the virtual prototype, viewers can get a sense of the

scale, spatial relationships, and aesthetics of the design. This allows the customer and

engineer to review and interact with product designs in their early stages.

Ship design for the royal navy U.K

The naval directorate of future projects of he United Kingdom has employed virtual design in

its new ship development program. Using Deneb robotics, Inc.s ENVISION software, the

quarterdeck of a new ship was interactively designed through simulation. It included the

ships motion and its effect on operating machinery, sailors and lighting conditions in the

ships compartments. This simulation allowed engineers to evaluate the design and

interactively change it as necessary .

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1.5 Digital prototyping in Indian context

In Indian market the use of digital prototyping tools is still on very small scale. Some of the

reasons for this are as follows:

1. Lack of knowledge or awareness regarding the technology. Only the larger OEMs

and companies know about these. The medium scale industries do not want change

their traditional techniques because of their mind-set regarding the profitability that

this technology can provide them in the near future.

2. Very high initial investments required to have these technology makes them less

popular amongst the investors.

3. Requires very highly skilled professionals to work on them .

4. Indian companies are lesser into research and development hence there are lesser

takers of this technology.

1.6 Remedies

1. The companies which are pioneering this technology should publicize the advantages

and uses of this technology.

2. Te technology must be made cheaper and marketed well to suit the Indian market.

3. Government should make policies to support and encourage the companies to use this

technology.

.



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CHAPTER 2

2.1 FUEL INJECTOR

A fuel injector is a device used to deliver metered quantity of fuel into engine cylinder head. It

works in combination with a high pressure pump, bringing fuel from the fuel tank to. From the

intake, the fuel passes through a filter to ensure the valve beneath doesn't get clogged with

sediments from the fuel tank. The pressure of the fuel within the injector holds down the valve,

preventing the gas from pushing into the combustion chamber. Suspended at the top of the valve

there is a small magnet above a spring and on the outside of the fuel filled injector there is an

electrical coil which surrounds the injector. As the electrical timing system of the engine decides

that it's the right moment to put fuel into the combustion chamber below the fuel injector, it sends

an electrical impulse to the coils. The magnet on top of the valve is attracted to this electrical

charge in the coils and raises the valve, unplugging the injector and causing the fuel to flow into

the chamber. In the next process, the electrical

charge is discharged\ and the spring pushes the

valve back down into place, closing the injector

until the next electrical signal is sent.

2.3 STEPS INVOLVED IN THE 3D

MODELLING

The individual parts of the fuel injector is created

in the CATIA modeling software and assembled

using the part designing and assembly platforms in

the software. Below are the description of how the

individual parts were modeled and assembled using the

software tool.

Fig 2.0 Fuel injector[3]



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Fig 2.1 Adjusting screw

Initially create a circle of required diameter and pad it to the required length. Then create theslot on the surface using the pocket option by creating the profile of the slot and then

pocketing it to the required depth. Now on the other side create the threaded hole of required

depth and type. Apply the required material



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Fig2.2 Body

Initially create the profile containing the wing like structure and pad it to the neededthickness. Build the square part on both sides of this profile using the same pad option.

Similarly create the cylindrical tube like structure and other forms use pad option .create holes

wherever it is needed. To create the inclined fuel delivery passage assume a path with angles

of 77 and 105 degrees and create the hole along this path. The angle and the path is more clear

in the 2D drawing of this particular part provided at the end of the report. Create the two

threaded holes as required. Provide chamfering and filleting to edges as required. Apply the

required material



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Fig 2.3 Cap

Create a rectangle profile whose width is equal to the thickness of the hollow cylindrical

shape to be generated and using shaft option create the hollow cylinder. Pocket the hole to

obtain step in the hole diameter and provide the threading on inner surface wherever it is

needed and fillet the edges wherever needed. Apply the required material



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Fig 2.4 Distance piece

Create the half profile of the distance piece and revolve the profile using the shaft option .

provide fillets to the edges. Apply the required material



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Fig 2.5 Lock nut

Create the hexagonal profile of the nut and extrude it to the required thickness. Using the hole

or groove option create the hole in between and then using thread option create thread for the

hole. Now to create the chamfered end create a triangular profile and using groove option

create the chamfer on one side and the obtain the mirror of the same on the other side. At last

apply the required material.



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Fig 2.6 Nozzle

Create the half profile pf the nozzle and using the shaft option obtain the basic shape of the

nozzle. Now make a single hole of dia 1.5mm and align the hole to a line which is at 1degree

inclination with vertical axis of the nozzle. Now using the circular pattern option create the

rest two holes. Provide chamfer to the edges and apply the required material.



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Fig 2.7 Nozzle holder

Create the half profile of the holder and rotate it using the shaft option . provide the threading

to the inner surface and apply the required material.



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Fig 2.8 Nozzle pin

Create the half profile of the pin and rotate it using the shaft option and apply the required

material.



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Fig 2.9 Screw adjuster

Create the half profile of the screw adjuster and rotate it using the shaft option. Providechamfer to the sharp edges and apply the required material.



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Fig 2.10 Spring

Create a circle of diameter equal to the diameter of the coil of the spring and using the

helix option create the curvature if the spring of the required length and pitch. Now use the rib

option to extrude the circle along the curve to obtain the solid model of the spring. Create two planes and using these planes split off the spring on either sides to the required length and

apply the required material to the model.



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Fig 2.11 Fuel injector Assembly

The assembly method in this case is top down method. All the components of the assembly

are called for in the assembly window and assembled one by one for inner to outer

components depending on their position in assembly and constrained respectively.



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2.3 Clash analysis

2.4Experience in developing the 3d model

The process of developing the 3D model has helped in learning the CATIA modelingsoftware thoroughly. The assembling of parts has helped in gaining better knowledge if the

constraints involved in assembly and the way the need to be assembled. Also the difference

between top-down and bottom-up methods of assembling. The modeling has also helped in

knowing the working of the fuel injector in a better way.

CHAPTER 3



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3.1 Reverse engineering

It is a process of developing a engineering design data from existing component, subassembly

or a product, without the help of design drawings or any kind of design documentation, or

computer model. It a time saving method where in the time spent on all the designing stageand testing or validating the design is saved. And since a already properly working product is

taken and re-engineered there is surety of the functionality of the design. All that is to be done

is to make changes in the design that could improve the functionalities of the product or

rectify any problems or errors mad in the previous design.

Typical steps involved in reverse engineering are:

1. Scanning the part using digitizer or scanner to obtain the point cloud.

2. Converting this point cloud into a polygon model or a mesh

3. Creating curves on the model or curves.

4. Create a restructured mesh.[4

5. Create a 3D model out of the mesh with the required dimensions.

6. Obtain the drawings of this design and manufacture the product and analyze it.

3.2 Sketch tracing method

It a method used in reverse engineering. It is used to obtain the 3D surface model of any

product from the existing 2D photograph of the product in the 3D modeling software CATIA.

The photo of the product for example a car is opened in CATIA and the outer feature of the

car is traced out using this technique. All the views are traced out and using all the views the

3D surface model is built in the surface modeling platform in the CATIA software.

3.3 Pick-up truck



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A pickup truck is a light motor vehicle with an open-top rear cargo area called as bed which is

almost always separated from the cab to allow for chassis flex when carrying or pulling heavy

loads[5. Used in country sides by the farmers or inn general by people requiring to carry small

loads in their daily activities. It has got a passenger cabin able to seat 2 or max 3 people and a

open bed behind to carry all sorts of loads.

3.4 Sketch tracing procedure

Open the Product in catia in that create a new part body, and then go to the sketch

tracer.

In sketch tracer call the images, to the required plane like (xy, yz, zx plane).

From sketch tracer go to the generative shape design, and then sketch the profile

using spline, arc, and lines.

Fig 3.1 Projections of all views

Then sketch is scaled to get the required dimensions.

First, bottom outlines are drawn from the top view.

After that the wrest line is created from using side and top view.

The roof is created by using front and side view.



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In that roof, the curves are created. By using the spline definition.

The guide curves are created in between the roof and wrest line by using the spline

definition and combine curve.

And by using curves the wire frame is generated for the bonnet by using top and side

view

The use of back and side view, back side wire frame is created (truck).

Wire frame of pickup truck is generated.

Fig 3.2 wireframe model

By using multisection, fill command the surfaces are generated.

Then all surfaces are joined, then for the

required height, the bottom surfaces are splitted.



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The sketch is drawn for the wheel according to the dimension, and then sketch is projected on

the side of the surface.

Then the surfaces is splited, then created the wheel by using extrude, fill command.

Then the bottom face is filled by using fill command. Then once again the surfaces are joined

Then joined surfaces are done the symmetry.

Fig 3.3 Rendered model isometric view

Cutting plane Analysis



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To check the tangency of the curve

Fig 3.4 Cutting plane analysis

Isophotes Mapping Analysis: This analysis is for to checking the surface roughness. In

some areas there is a rough surface .

Fig 3.5 Isophotes Mapping Analysis

Environment mapping analysisModern Automotive Systems

21


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Fig 3.6 Environment mapping analysis

3.5 Additional features

The Rear view mirrors

The plane is generated in the required position, and then sketch is drawn. By using the

multisection the mirror is generated, and the same mirror is done the symmetry.

Wheel cover

On the separate part body the point and planes are created to create the wheel cover. The

sketch is drawn in xz plane. By using the multisection command the wheel cover is created .

Radiator grill

The surface is extracted from the front side. The sketch is drawn in yz plane and projected on

the extracted surface. Then using the split command, cut the profile and radiator grill is

generated.



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Fig 3.7 Final rendered model isometric view

3.6 Experience in developing model

The process of obtaining the 3D surface model from a 2D drawing of the pick-up truck using

the sketch tracing method has helped in gaining knowledge of aspects involved in reverse

engineering. The easiness and the quickness the method provides us in obtaining the final

model. And the scope for potential improvement that can be made in the design in lesser time.



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CHAPTER 4

4.1 Module learning outcomes and summary

The module has given a picture of what is CAD/CAM/CIM. It has helped us in providing

knowledge regarding the various developments in these fields. Some latest technologies like

digital prototyping , virtual sculpting, motion capture technique and all sort of techniques that

are being used in automotive, gaming, animation and entertainment industry.

The module has also given us insight into product life cycle. The various aspects associated

with it like product life cycle management, product data management etc. The engineering

drawing basics were also nicely covered up. The session on GD&T was useful in gainingknowledge about the standard and how they are used.

The lab sessions were useful in learning 3D modeling as well as the basics of reverse

engineering process. And of the method of reverse engineering that is sketch tracing. The

special sessions designed for reverse engineering, rapid prototyping and CAM were useful in

knowing about the CNC programming, various operations involved in CNC milling, the uses

of Digital gloves and eye gear HMD etc were well described.



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REFERENCES[Referring a Book]

[1] Kunwoo lee, CAD/CAM/CAE, 4th Edition, Wiley & Sons, USA, 1999.

[Referring Web Published Article][2] Metrocar2000, www.adtranz.com Retrieved on 26 th nov. 2009[3] https://reader010.{domain}/reader010/html5/0626/5b322958ed1ea/5b322977d822e.jpgretrieved on 08-12-2009

[Referring Course Notes][4] Harshal sawant., Computer aide engineering , Course Notes, M.S. Ramaiah School of

Advanced Studies, Bangalore, dec 2009.

[Referring Web Published Article]

[5] Pick up trucks , www.wikipedia.com , Retrieved on 1st

dec. 2009

http://www.tapiaenterprise.com/valve.jpghttp://www.wikipedia.com/http://www.wikipedia.com/http://www.tapiaenterprise.com/valve.jpghttp://www.wikipedia.com/


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BIBILIOGRAPHY

1. Kunwoo lee, CAD/CAM/CAE, 4th Edition2. Harshal sawant., Computer aide engineering , Course Notes, M.S. Ramaiah School of

Advanced Studies

3. wikipedia.com

4. adtranz.com

5. pdfdatabase.com

6. BOSCH handbook 6th edition

Bybo909029 Apd r Amith Kumar

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