Post Graduate Program in Complete Passenger Car Design & Product Development

Vehicle development cycle

• This is an introductory session where you will be introduced to the basics of automobiles along with different models of car bodies.
• You will learn about the different stages of vehicle development that a car will go through before reaching the customer.
• You will also learn about the three years of development activity that precedes the development of an automotive model.

Basics of Automotive Body in White

• In this session, you will be introduced to the basics of automotive BIW.
• You will be introduced to the basics of steel and its properties in detail as steel is an important component used in the construction of automobiles.
• The steps that are followed in the selection of the material will be discussed as well.
• You will be given an introduction to cross-functional teams that exist in an organization, and the need to coordinate with them along with examples of master sections and 3D components of the parts for easy and clear understanding.

Design Methodology of a Hood, Fender, Roof, Back Doors, and Side Doors

• In this module, we will focus on the Hood, Fender, Roof, Side doors, and Back doors.
• The design procedures for all the afore-mentioned parts can be summarized as follows,
  • Design Requirements
  • Functional Requirements
  • Regulations
  • Gap and Flushness Requirements
  • Safety Requirements

Case study - Converting - Backdoor/Tailgate Inner Panel

• In this module, we will present a real-life scenario where the effect of converting an inner panel from aluminium cast to the steel deep draw part will be shown.
• Here is a quick summary of this case. The following design parameters were identified as critical and hence were fully described:
  • The seal surface width was the same as the aluminium liftgate
  • Tailgate outer parting was maintained as the same
  • Liftgate thickness was modified
  • Gap and flushness were maintained
• You will be able to clearly understand these design parameters and the decisions that were made.
• In this case study, the design guidelines were set through a series of CAE simulations.

Design of key mechanism - Lock and Striker

• In this module, you will study the anatomy of a Locker and Striker mechanism.
• In order to be a successful product development engineer, it is very important to understand in detail the development process and design requirements for even the smallest component.

Case study Process and challenges with supplier manufactured parts

• In this module, we will look at two case studies.
• Both of these studies focus on supplier manufacturing practices.
• We will discuss the design challenges faced by two Asian Automotive suppliers and then go over the solution methodologies

Design Overview In Automotive Industry

• In this session, you will learn
  • Product Life Cycle
  • Design Life Cycle

Plastics in Automotive Industry

• In this session, you will learn
  • Types of plastics (Thermoset Plastics, Thermoplastic)
  • Engineering plastic Materials
  • Manufacturing Process
  • Injection Molding

Introduction to CATIA

• In this session, you will learn
  • Basic commands and operation
  • Save feature, pan feature, rotate feature, etc

Sketcher workbench

• In this session, you will learn the following
  • Commands
  • Rules to follow
  • Working in exercise

Part Design Workbench

• In this session, you will learn
  • Pad and pocket
  • Working on exercise

Advanced part design

• In this session, you will learn
  • Boolean operations
  • How to work on a Boolean exercise
  • How to work on After Tool Go modification on Automotive components. (OEM Working procedures)

2D Drawing creation

• In this session, you will learn to
  • Create a PCB Bracket using Boolean operations

Basic Surface Design Workbench

• In this session, you will learn the following 
  • Commands (Types of Sweep)
  • Working on exercise
  • Draft analysis
  • How to work on a surface exercise

Advanced Surface Design Workbench

• In this session, you will learn the following 
  • Commands 
  • Creation of Closed body, Thickened body
  • A parting line and parting surface

Creation of Door Switch Bezel and adding thickness to it

• In this session, you will learn  
  • How to create tooling direction and do the draft analysis to ensure the part can be taken out of the tool?
  • Adding the right thickness to the part and solving the issues.
  • Create the parting line for the bezel.

Tooling Feasibility

• In this session, you will learn  
  • What is a mounting feature?
  • How to create a locator and dog house?
  • Integrating the mounting features to the base part with Boolean operations

Modeling Exercise

• In this session, you will learn  
  • The Clip mounting feature is in Plastic design.
  • Design considerations for creating this feature
  • Tooling analysis for the clip feature

Drafting Workbench

• In this session, you will learn  
  • Drafting workbench
  • Creation of detail drawing for the Components
  • Views creations (basic view & section views)
  • Application of GD&T in drawings
  • Template settings

Mold Design Considerations

• In this session, you will learn  
  • Creation of Paring line
  • Creation of Tooling axis
  • What is undercut and how to solve it

Complex Mold Design Parameters

• In this session, you will learn
  • Creation of simple mold for the Rear quarter trim Cupholder
  • What are core and cavity
  • Stripper, ejection, and system
  • Draft analysis  
• Designing a mold gives a good working understanding of the molding aspects of a component

Basics of Vehicle Electrical Distribution System & Wiring Harness

• In this session, you will learn
  • Introduction to Vehicle Electrical Distribution System (EDS) 
  • Introduction to wiring harness assembly
  • Wiring harness design process for New Product Development (NPD)
  • Introduction to CATIA V5 electrical workbench

Introduction to CATIA V5 Electrical Workbench & Electrical Part Design

• In this session, you will learn
  • Customized settings for electrical environment
  • Wiring harness routing process for CATIA V5
  • CATIA V5 – electrical part design

Electrical Part Design

• In this session, you will learn
  • Clip/clamps/support part definition
  • Backshell definition
  • Protective covering definition

Harness Assembly & Installation – Part 1

• In this session, you will learn
  • Preparation of harness assembly
  • Creating the wire harness geometrical bundle
  • Inserting harness components into a geometrical bundle
  • Positioning your inserted electrical parts
  • Connecting & Disconnecting electrical components
  • Defining the wiring harness routing

Harness Assembly & Installation – Part 2

• In this session, you will learn
  • Wiring harness routing on external references 
  • Modifying the wire harness bundle segments
  • Wire harness protective coverings
  • Use of electrical splices
  • Bundle continuity check/analysis
  • Geometrical bundle warnings
  • 3D annotation

Harness Assembly & Installation – Part 3

• In this session, you will learn
  • Modifying the wire harness bundle segments
  • Modifying the branch point location
  • Deleting bundle segment
  • Bundle continuity check/analysis
  • Geometrical bundle warnings
  • 3D annotations
  • Important commands, tips, & techniques

Wiring Harness Flattening

• In this session, you will learn
  • Wiring harness flattening workbench
  • Flattening workbench settings
  • Flattening the 3D harness assembly
  • Modify flatten assembly
  • Saving the flatten files
  • Drawing, creation & contents

Component Specifications & Selection Guide

• In this session, you will learn
  • Wiring harness component specifications & selection parameters
  • Available suppliers in the market (India)

Wiring Harness Routing & Packaging Basics – Session 1

• In this session, you will learn
  • Definitions
  • Routing & packaging process
  • Design criteria (generic) for wiring harness 
  • Packaging rules & best practices
  • Guidelines for battery cables routing

Wiring Harness Routing & Packaging Basics – Session 2

• In this session, you will learn
  • Clearance management
  • Water ingress protection
  • Thermal protection management
  • Chaffing protection
  • Vibration protection
  • Routing on/near dynamic parts ( engine, wheel)
  • Harness bending rules (harness & battery cables)
  • Interconnection connector parking

Week 01 - Digital Design Foundation 1, Curves Introduction & Why Use Curves

• In this session, you will learn
  • Introduction to ALIAS
  • What is Design? About CAID/CAD Design
  • User interface and Navigation Tools
  • Basic Object Selection and viewing
  • Importing Sketches as images or canvases
  • Working with layers
  • Introduction to curve tools. Basics, U’s & V’s, spans.
  • Create Symmetrical Curves
  • Transform Curves, Creating Curve Fillets, Curve Sections and offset curves

Week 02 - Digital Design Foundation 2 & Building and Controlling Simple Geometry

• In this session, you will learn
  • Controlling Geometry, Mirroring, Grouping, and Duplicating Objects 
  • Object Lister, CV Sculpting, and Concept Sculpting

Week 03 - Digital Design Foundation 3, Surface Editing & Introduction to Different Continuities

• In this session, you will learn
  • Surface toolbar, edit and shade
  • Difference Between Surfaces and Solids
  • Surfaces from Boundaries
  • Bezier Surfaces 
  • Nurbs & Slab Modeling
  • What are Parent Surfaces?
    • Primary Surfaces
    • Secondary Surfaces
  • Sharp Surface Models
  • Primary Fillets and Blends
  • Secondary Fillets and Blends
  • Chord Fillet and Radius Fillet
  • Trimming, Creating Curves on Surfaces
  • Trimming Surfaces, Intersect Surfaces, Filleting Surfaces
  • Adding Variable Radius Fillets
  • G0 - Positional
  • G1 - Tangent
  • G-2 - Curvature
  • G-3 - Curvature

Week 04 - Workflow 1: Concept Modeling

• In this session, you will learn
  • Introduction to Concept Modelling 
  • Introduction to Construction Options
  • Dimensions 
  • Overlay Canvasses for Design and Presentation 
  • Building with Curves & Surface Tools 
  • Modelling Approaches and Surface Distribution 
  • Working Accurately

Week 05 - Workflow 2: Concept Modelling

• In this session, you will learn
  • Overlay Canvass for Design
  • Surface Understanding by Three-quarter Views
  • Building with Curves & Surface Patching 
  • Modelling Approaches and Surface Distribution

Week 06 - Workflow 3: Concept Modelling

• In this session, you will learn
  • Component design 
  • Hypothetical surfaces to create patch layout 
  • Work more on the Creative side: Imagine the surfaces

Week 07 - Workflow 4: Concept Modelling

• In this session, you will learn
  • Component design 
  • Hypothetical surfaces to create patch layout 
  • Work more on the Creative side: Imagine the surfaces

Week 08 - Workflow 5: Concept Modelling

• In this session, you will learn
  • Surfaces, patches, and layout 
  • The idea of how to divide surfaces 
  • Building techniques, and where to start 
  • Make your way up to the top 
  • Parent Patches- Foundation

Week 09 - Technical Surfacing (A- Class Knowledge)

• In this session, you will learn
  • Introduction to Technical Surfacing
  • Surface Evaluation - Reflection Lines
  • Surface Evaluation - Cross Sections & Comb Plots
  • Construction Tolerances between Surface Patches
  • Transform CV - Fine-Tuning Control Points
  • Working with Trimmed Edges - Fit Curve & Align Project

Week 10 - Class B Surfaces Modelling

• In this session, you will learn
  • A well-thought patch construction 
  • Patches with proper CV layout 
  • Proper passing of positional, tangent, and curvature surfaces 
  • Properly evaluated surfaces 
  • Making way up to Class-A Model

Week 11 - Reverse Engineering

• In this session, you will learn
  • Introduction to Reverse Engineering 
  • Working with Mesh Data 
  • Working with Sections 
  • Creating a Surface onto a Mesh 
  • Analyzing and Displaying Deviation 
  • Reference Manager for Handling Large Data Sets

Week 12 - Presenting Your Design

• In this session, you will learn
  • Rendering in ALIAS
  • Hardware Rendering, Shades, Lighting and Environments 
  • Creating Image Files

Basic of Lighting & Software Overview

• In this session, you will learn
  • Some Old school phenomena of Physics-related to lighting
  • How basic physics are used in real-time application
  • Basic name and application of Automobile lighting Eg., Headlight, tail light etc. 
  • The function of light, eg., Turn indication, High beam, Low Beam
  • CATIA basic model, workbench, some basic commands (in CATIA)
  • Some practice sessions on basic features, Like, boss, Locators (in CATIA)

Basic of Regulation & Start of Making Lamp

• In this session, you will learn
  • Information about regulations and their function
  • Start making Lamp (Class A analysis) (in CATIA)
  • B surface creation (all into separate parts in CATIA) 
  • Feature implementation (in CATIA)
  • More deep information for Regulation and How to Check into 3D
  • Draft analysis, Basic check for Model(in CATIA)

 Advance Level of Regulation with 3D Model & Plastics Introduction

• In this session, you will learn
  • Basic Plastic, understanding while designing parts (in CATIA)
  • Making joining section (Glue, hot plate, Vibration etc)
  • Making all in single files (in CATIA)
  • Publish command in CATIA and join all parts together
  • Making mounting concept with 3,2,1 Principle surrounding check (in CATIA)
  • C regulation into 3D (in CATIA)

Basic Tooling Check & Drawing Making

• In this session, you will learn
  • Data as per tooling requirement(only basic) in CATIA
  • Start making a 2D drawing from 3D (in CATIA)
  • Tolerance and Dimension (in CATIA)
  • Complete revision (basic only)
  • Making small Lamp again as per regulation, plastic, and Tooling requirement
  • Understanding Industry requirements, Optics, thermal, RFQ, and other key elements to getting into this domain  

Introduction to Automotive Seating

• In this section, we will have a brief Introduction to Automotive Structure, Seats & their Nomenclature.

Current Fashion/Trend

• In this section, we will have a brief on types of Seats, how the seats are defined as per the number of rows in the Car and Number of Movement in the seat.

Component of Seats

• This section contains information about the parts/component used to design/develop a seat as per the requirement from the customer. It will also have a basic mechanism used in a seat to provide the movements. It is defined in two segments:
  • Front Row Components 
  • Rear Row Components

Component Details : Foam

• In this section, we will brief about the components of Foam.
• The following points will be covered during the course with a hands-on CATIA model.
  • How many types of Foam are available
  • Design Standard for Foam
  • Methods of foam development/Manufacture
  • Defects in Foam

Component Details : Structure

• In this section, we will brief about the components – Structure.
• The following points will be covered during the course with a hands-on CATIA model.
  • Types of Structure
  • Component of Structure
  • Design guideline
  • The material used in manufacturing
  • Methods used to develop a structure

Component Details : Headrest

• In this section, you will learn the following.
  • Types of Headrest used in automotive seats.
  • Components used in making headrest
  • Use of Headrest

Component Details : Trims

• In this section, you will learn the following.
  • Types of Trims used in Automotive
  • The terminology used in Trims
  • Defects during the development of trim
  • Methods to assemble trims

 Component Details : Plastics

• The following points will be covered during the section:
  • Types of Plastic ( Material/Usage differentiation)
  • Nomenclature of plastic parts in the seat
  • Efficient ways to use plastic in a seat
  • Defects occur on plastic components

Component Details : Armrest

• In this section, you will learn the following.
  • Types of Armrest
  • Mechanism of Armrest
  • Components of an Armrest
  • Manufacturing Defects of Armrest

 Component Details : Mechanism

• In this course we will brief about details of all the mechanisms used in Automotive passenger seats including types of Mechanism used and nomenclature:
  • Recliner – Work/Function and detail study
  • Track – Work/Function and detail study
  • Height Adjuster – Work/Function and detail study

Seat Testing

• This course will provide a glimpse of testing of seats at Car/Seat level which will include below:
  • Safety-related Test
  • Regulatory related Test

Comfort and Innovation

• This course will provide a glimpse of testing of a seat at Car/Seat level which will include below :
  • Comfort mechanism
  • New Innovation Idea
  • Comfort layouts of Seats

Seat Related Issues

• This section of the course will not only be generalized to seating but this method can be used all over the globe in any design-related program:
  • 8D
  • Fish Bone Diagram
  • 5D
  • Man-Machine Diagram

 DFMEA and PFMEA

• This section of the course will not only be generalized to seating but this method can be used all over the globe in any design-related program :
  • What are DFMEA and PFMEA
  • The process to prepare DFMEA and PFMEA
  • Different Review points of DFMEA and PFMEA

Geometric Dimensioning and Tolerances [GD&T]

• This section of the course will not only be generalized to seating but this method can be used all over the globe in any design-related program :
  • Introduction to GD&T
  • Usage of GD&T in seats
  • Different examples to define GD&T with exercise to do

Program Life Cycle

• This section of the course will not only be generalized to seating but this method can be used all over the globe in any program :
  • Life Cycle of a program
  • Different stages a program goes
  • Milestones of Customers