RUPD

Customers Objective
Mass and Cost Effective different metals parts for commercial vehicle using advanced FRP material
Design Phases :
Concept Design
Proto Phase
Manufacturing Phase
Duration

11 months

Inputs Provided
Reference data of (CAD Data-2D/3D)
Carry-over parts CAD-2D/3D
Exploded views of Assembly (Images)
Bill of Material
PCPL’s Solution :
Initial concept design
Generate CAD model
FEA simulation for Transient Analysis, Modal Analysis, Vertical Load- 5g, Braking -3g, Longitudinal+1g Vertical, Cornering- 3g, Lateral+1g Vertical.
Detail design ready with CAD models, thickness and fillets provided, Manufacturability with Composite rules.
Detailed engineering
Manufacturing drawing
Complete clash and interference analysis for all these component
Deliverable
Different Concepts Developed Into Concrete Designs and Evaluated for Mass, Performance, Cost and Manufacturability
Concept 1 : New Material (FRP Pultrusion)
Concept 2 : Optimized mass (New Topology)
Concept 3 : New Topology and material (Easy Assembly)
Manufacturing feasible final design
Design Steps
Component Concept generation.
Generation 3D CAD model.
Analysis of Concepts, optimization of each concepts for mass.
Pugh matrix for comparing 3 concepts in terms of Mass, manufacturability, cost and Selection Of Final Concept
Manufacturing Feasibility and Cost Analysis
Design Optimization and Final design
CONCLUSION
The total mass reduction achieved in the modified case is 11.6 kg
Overall 26% mass reduction.
Improves power to weight ratio.
Cost reduction by 15%.
Simplifies assembly of the system.
Reduces production cost, inventory and labor cost etc.
Download Automotive contains