Automotive

CAD – Design Engineering Projects:

Bus Body Design Engineering & Prototype development as per standards
BIW - 3D CAD modelling of bus body, parts, sub-assemblies, interior & exterior trimming parts, detail engineering & release of 2D production drawings with bill of material.
Automotive Interior / Exterior / Lighting systems Surface / Solid 3D Modelling, 2D Drafting & detailing.
3D CAD Modelling, detailing of interior / exterior trim parts from given concepts / ‘A’ class surfaces
Parametric Modelling, B-Features creation, Tooling Direction & Parting line for several automotive plastic parts & assembly.
Design modification of a pickup truck.
Bus AC rooftop composite design engineering considering aerodynamic feasibility and manufacturability of the component from provided styling surface model.
Creation of solid 3D model & 2D Drawings from given surface models of several automotive parts & assemblies.
Design Engineering of Seating systems & mechanism for Bus & Cars as per standards requirement.
Legacy data conversion, 3D CAD modelling, 2D Drafting & detailing of Engine and Transmission system parts & assembly.
Seating systems design engineering as per standard codes.
Axle & Suspensions system’s 3D & 2D drawings
3D & 2D support in Exhaust system.
Electric Vehicle Batter pack design Engg, and replaceable battery mechanism system design.
Lagacy CAD data conversion / migration of several auto parts & assemblies.
Prototyping of front grill & wheel cover for a passenger car.
3D renderings and 3D Animation videos.
Animation of Car tyre inflating system
Vehicle integration of accessories such as racks inside a Land Cruiser vehicle, along with a roof-mounted antenna receiver.

Revere Engineering / 3D canning:

3D Scanning / Reverse engineering of several Four, three & two-wheeler vehicle’s parts & assemblies.
Reverse Engg of Bus Chasses
3D canning of complete exterior of a car
Revere engineering of front bumper of a car
3D canning & inspection of Engine block & other casting parts

3D canning / Reverse Engg of an automotive seating
Two-wheeler 3D scanning of exterior and closures. Closures to be tear down to part level and scan all parts. Tear down scans to be integrated into common datum per assembly scan. Then 3D Model generated and aligned accordingly.
Reveres Engg of a Head lamp
Reveres Engg of a disc brake assembly

Prototype development:

CAE – FEA / CFD Analysis / Virtual Test Simulation / Design Validation Projects:

FEA Test Simulations / Analysis-

FE Mesh modelling of several interior, Exterior, Powertrain systems parts and other Automotive ancillaries like Dashboard, Console, lighting, bumper, fender, engine assembly, cradle assembly, Suspension system, Transmission system and muffler assembly etc,
Vehicle (Bus / Cars) crash test simulations.
Dynamic Analysis of engine fly wheel.
FEA of Cylinder Head Cover.
Torsional Vibration Analysis (TVA) of engine driven pump powertrain.
Engine mounting bracket FE Analysis under road load cases / conditions
Modal & Stress analysis of Mufflers / exhaust systems.
Bus Rollover analysis and certification from CIRT as per AIS 052 bus code.
FEA to find cause of CNG & Diesel engine Bus chassis field failure analysis.
FE Analysis of a truck trailer under road load cases like Panic braking, Bump & cornering with 25ton load & speed 120kmph.
Roof Crush test analysis of passenger car as per FMVSS regulations and modify the structure to increase the resisting load by 10kN.
Static & Dynamic Analysis of Vehicle Chassis
Seat folding Mechanism Simulation and modifications for achieving the desired motion limits (Jerk and Accelerations).
Multi-body Dynamics Simulation to predict the torque required for Torque calculation of a powered seat folding mechanism.
Fatigue Analysis of wheel rim.
FEA of Rear Axle
FEA to understand the behaviour & failure of bearing & knuckle under specified road load cases & to carry out design modifications to meet the targets. /Failure / Behaviour analysis of a bearing & knuckle.
Modal Analysis of 3-Wheeler fender -Transient and frequency response analysis.
Fatigue Analysis of Knuckle
FEA Simulation and design optimization of a two-wheeler front fork & rear shock absorber.
Torsion Stiffness Analysis of bust body structure
Suspension – Stiffness & Durability Prediction, shore hardness
Rebound Stopper – CR & NBR
Offset Frontal Impact and structure optimization for achieving customers’ proprietary requirements, io carry out structural modifications to reduce the intrusion levels in the Dashboard, A-Pillar and Booster Locations by 20%, 25% and 30% respectively.
FEA Roof Crush as per FMVSS 216 regulations and modify the structure to increase the resistance load by 10 kN
FEA to simulate using Pedestrian Head Impact on the bonnet in order predict Head Injury Criterion Value (HIC).
Stress Analysis of a plastic wiper assembly.
Stress Analysis on a Head Lamp Assembly for determining the clamping locations which would give maximum rigidity to the assembly
Sheetmetal Stamping-Forming - Manufacturability simulation in order to predict possibility of tearing and wrinkling in bending process adopted for manufacturing an underbody long member of a Car.
Knee Bolster optimization - To optimize the thickness of the Aluminum knee bolster so as to bring it’s the Load Vs Deflection Characteristic with a specified band. Non-Linear Analysis was carried out, and it took 7 modification iterations and analysis to arrive at the desired characteristic.
Blow molding simulation
Injection Molding simulation – Thermoplastic and Thermoset