Bybo909029 Apd R Amith Kumar

COMPUTER AIDED ENGINEERING
POSTGRADUATE ENGINEERING AND MANAGEMENT

ASSIGNMENT
Centre Name: A.P.D

Course Name: M.Sc. [Engg.] in Automotive Product
Design
PROGRAMME (PEMP)
Name of the Student : R AMITH KUMAR
Student Registration No : BYB0909029
Module Leader at MSRSAS : HARSHAL
SAWANT
FULL TIME 2009 BATCH
M. S. Ramaiah School of Advanced Studies

New BEL Road, Gnanagangothri Campus, MSR Nagar, Bangalore-560 054
Tel: 23605539 / 23601983 / 2360 4759. Fax: 2360 1923
website: http://www.msrsas.org
M.S Ramaiah School of Advanced Studies –Postgraduate Engineering and Management Programme (PEMP)
Declaration Sheet
Student Name R AMITH KUMAR
Reg. No BYB0909029
AUTOMOTIVE PRODUCT
Course Batch FT-2009
DESIGN
Module Code AME501
Module Title COMPUTER AIDED ENGINEERING
Module Start Date 09/11/2009 Submission Date 7/12/2009
Module Leader HARSHAL SAWANT
Submission Arrangements
This assignment must be submitted to Academic Records Office (ARO) by the submission date before 1730
hours for both Full-Time and Part-Time students.
Extension requests
Extensions can only be granted by the Head of the Department / Course Manager. Extensions granted by any
other person will not be accepted and hence the assignment will incur a penalty. A copy of the extension
approval must be attached to the assignment submitted.
Late submission Penalties

Unless you have submitted proof of Mitigating Circumstances or have been granted an extension, the penalties
for 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 (F2)
All late assignments must be submitted to Academic Records Office (ARO). It is your responsibility to
ensure that the receipt of a late assignment is recorded in the ARO. If an extension was agreed, the
authorization 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 the
assignment questions. Each participant is required to retain a copy of the assignment in his or her record in
case 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
Date
Delegate
Date Stamp from Signature of ARO

ARO Staff
Modern Automotive Systems

ii
Signature of Signature of
Module Leader Course Manager

iii
M. S. Ramaiah School of Advanced Studies

Postgraduate 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 Completion
Module Leader Harshal sawant 5/12/2009
Date
Student Name R Amith kumar ID Number BYB0909029
Attendance Details Theory Laboratory Fine Paid Remarks
(if any for shortage of attendance)
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 FAIL
Assignment – Marks-Sheet (Assessor to Fill)
Part a b c d Total Remarks
A
B
C
Marks Scored for 100 Marks Scored out of 50
Result PASS FAIL
PMAR- form completed for student feedback (Assessor has to mark) Yes No
Overall-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
IMPORTANT
1. The assignment and examination marks have to be rounded off to the nearest integer and entered in the respective fields
2. A minimum of 40% required for a pass in both assignment and written test individually
3. 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

iv
Abstract
Chapter 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 scenario
regarding 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.
Table of Contents
Abstract.......................................................................................................................................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 Figures
Fig 2.1 Adjusting screw……………………………………………………………………………
5
Fig 2.2 Body………………………………………………………………………………………...6
Fig 2.3 Cap…………………………………………………………………………………………..7
Fig 2.4 Distance piece…………………………………………………………………………….8
Fig 2.5 Lock

nut……………………………………………………………………………………..9
Fig 2.6
Nozzle……………………………………………………………………………………….10
Fig 2.7 Nozzle holder………………………………………………………………………………

11
Fig 2.8 Nozzle pin…………..

……………………………………………………………………….12
Fig 2.9 Screw adjuster…………………………………………………………………………..…

13

ii
Fig 2.10
Spring……………………………………………………………………………………….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 analysis……………………………………………………………………

21
Fig 3.5 Isophotes mapping

analysis…………………………………………………………….21
Fig 3.6 Environment mapping analysis…………………………………………………………

22
Fig 3.7 Final rendered model isometric

view………………………………………………….23

iii
Nome
nclature
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

iv
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 competitor’s product is launched[1]. Traditionally product development
was based on design iteration’s & 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 it’s 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.
Some of the companies that have product or service relate to Digital Prototyping are
Autodesk, Dassault Systems, Siemens PLM Software, PTC, and Rhinoceros. Providing
software’s 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 see
cause-and-effect and track things we can’t 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:
Stockholm’s Metrocar 2000[2]
Metrocar 2000 is Stockholm’s new public transportation system designed by Adtranz

Sweden. Using division’s 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
ship’s 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.

2
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 OEM’s
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.

3
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]

4
Fig 2.1 Adjusting screw
Initially create a circle of required diameter and pad it to the required length. Then create the
slot 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

5
Fig2.2 Body
Initially create the profile containing the wing like structure and pad it to the needed
thickness. 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

6
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

7
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

8
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.

9
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.

10
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.

11
Fig 2.8 Nozzle pin

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

12
Fig 2.9 Screw adjuster

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

13
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.

14
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.

15
2.3 Clash analysis
2.4Experience in developing the 3d model
The process of developing the 3D model has helped in learning the CATIA modeling
software 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

16
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 stage
and 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

17
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.

18
• 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.

19
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

20
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 analysis

21
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.

22
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.

23
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 gaining
knowledge 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.

24
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 26th nov. 2009
[3] http://www.tapiaenterprise.com/valve.jpg retrieved 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

25
BIBILIOGRAPHY
1. Kunwoo lee, CAD/CAM/CAE, 4th Edition
2. 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

26

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COMPUTER AIDED ENGINEERING

POSTGRADUATE ENGINEERING AND MANAGEMENT

Centre Name: A.P.D

FULL TIME 2009 BATCH

M. S. Ramaiah School of Advanced Studies

Module Title COMPUTER AIDED ENGINEERING

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

Module Leader HARSHAL SAWANT

Late submission Penalties

Date Stamp from Signature of ARO

Modern Automotive Systems

Modern Automotive Systems

M. S. Ramaiah School of Advanced Studies

Written Examination – Marks – Sheet (Assessor to Fill)

Signature of Reviewer with date Signature of Module Leader with date

Modern Automotive Systems

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

Fig 2.2 Body………………………………………………………………………………………...6

Fig 2.3 Cap…………………………………………………………………………………………..7

Fig 2.4 Distance piece…………………………………………………………………………….8

Fig 2.5 Lock

Fig 2.7 Nozzle holder………………………………………………………………………………

Fig 2.8 Nozzle pin…………..

Fig 2.9 Screw adjuster…………………………………………………………………………..…

Modern Automotive Systems

Fig 2.11 Fuel injector assembly………………………………………………………………..

Fig 3.1 Projection of all views ……………………………………………………………………

Fig 3.2 Wireframe model …………………………………………………………………………

Fig 3.3 Rendered model isometric view ………………………………………………………

Fig 3.4 Cutting plane analysis……………………………………………………………………

Fig 3.5 Isophotes mapping

Fig 3.6 Environment mapping analysis…………………………………………………………

Fig 3.7 Final rendered model isometric

Modern Automotive Systems

CAD Computer aided design

Modern Automotive Systems

1.2 DIGITAL PROTOTYPING

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

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

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

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

1.3 ADVANTAGES WITH DIGITAL PROTOTYPING:

1.4 Industry application cases of virtual engineering:

Stockholm’s Metrocar 2000[2]

Metrocar 2000 is Stockholm’s new public transportation system designed by Adtranz

Ship design for the royal navy U.K

Modern Automotive Systems

1.5 Digital prototyping in Indian context

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

Modern Automotive Systems

2.1 FUEL INJECTOR

2.3 STEPS INVOLVED IN THE 3D

The individual parts of the fuel injector is created

Fig 2.0 Fuel injector[3]

Modern Automotive Systems

Fig 2.1 Adjusting screw

Modern Automotive Systems

Modern Automotive Systems

Fig 2.3 Cap

Modern Automotive Systems

Fig 2.4 Distance piece

Modern Automotive Systems

Fig 2.5 Lock nut