Project: Automation of the transformer design process through generation of parametric assembly modeling
Overview: BHEL is India's largest turnkey supplier of power plant and power transmission equipment. The transformer design process involves design of various components and their assembly.
To automate the design process, the individual parts were parametrically modelled. The parts were then joined together digitally to create 3D subassemblies, most of them parametric in nature. The final step involved generation of a fully assembled 3D model of the transformer and the automated generation of the 2D, fully dimensioned, manufacturing drawings as per BHEL standards. The assemblies can now be generated through the data in an Excel sheet or direct input through specially designed input screens. * Total no. of parts modelled = 825 * Total No.of subassemblies = 24 * Total No. of assemblies = 10
Project: Plastic Flow Study of TV Rear Cabinet
Overview: GE Plastics, a division of the Fortune 500 General Electric (GE) group, is a world leader in Plastic Material manufacturing. The assignment was to perform a plastic flow study and determine the feasibility of molding a TV rear cabinet with Noryl (a highly viscous plastic material).
This involved creation of 3D model of the cabinet and performing flow and design iterations with Noryl as the plastic material.The final result was achieved by providing eight gates with hot runner manifold. Verification of these results was done at the office of GE Plastics, where the entire model was converted to midplane mesh with 20,000 triangular shell elements and subjected to analysis. GE Plastics have accepted the study, and the data has been sent for manufacturing at their Japan plant.
Project: Development of CAD profile for generating point co- ordinates of automotive glass templates.
Overview: Asahi Glass, a Fortune 500 company, is the market leader in specialized Glass products for the automotive industry. The project involved generating the CMM data for the templates with predefined tolerance limits so that optimum number of points is available without loss of accuracy. For a simple profile, the number of points was decided to be less than 70 while for complex profiles, it was decided to keep it less than 100. Then the wireframe was created using CATIA and a smooth curve generated.
Client:
Research Designs & Standards Organization (RDSO), Indian
Railways
Project: Finite Element Analysis (FEA) of
a Wheel, Rail and Steel Block Assembly 
Overview: The project involved Modeling of
wheel, rail, and steel block, creation of the Assembly model followed
by generation of the FE Model and analysis of the same under given load
conditions.
The meshing of the assembly was done on the following conditions : Wheel and Steel block was meshed with TET10 elements, with a mesh density of 5-6mm. For radial elements, a 2 degree element was used for meshing. Rail was meshed Tetrahedrally using Beam element. Thin shell element of thickness 0.1 meshed on the surface of both the wheel and steel block with coincident nodes was merged for addressing the contact area between the steel block and the wheel.
Project: Conversion from 2D to 3D Models
Overview: Asea Brown Boveri, a Fortune 500 company, is a multi product, multi dimensional manufacturing company. As a part of their Design Reuse initiative, which aimed at reviewing processes to ensure faster "time to market" with reduced product cycle time, they decided to convert their 2D AutoCAD drawings to intelligent Pro - Engineer 3D models. From the 2D drawings, the component models were initially created and then the sub-assembly was developed using the parametric component models.
Project: Volume Verification Study of Molds
Overview: Hindustan National Glass Company, India's leading Glass manufacturer, are well known for their value added Glass products.
For one of their Wine bottle range, they wanted to deploy CAD/CAM capabilities for volume verification study of the molds. This involved modeling of the complex wine bottle with its complete styling and surfaces, and performing the volumetric studies for the mold. This was executed successfully, where the external volume calculations matched the desired need.
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