HCL Technologies

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HCL Technologies

• Engineering Services Practice

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Mechanical Engineering Services Throughout the
Life Cycle
Prototyping, Manufacturing Testing
Industrial design
Engineering
Analysis
CAD Modeling Documentation
Feasibility studies Concept generation Styling
and ergonomics Packaging Study
Detailed design (assemblies and
components) Design maintenance Cabling, piping
routing schematics Reverse engineering Value
engineering
Meshing Analysis Static, dynamic, fatigue, NVH,
rigid body, crash CFD analysis
Prototyping Tool design plastics, sheet metal,
casting Jigs and Fixture design Tool path
generation Mould flow analysis Testing Fatigue,
humidity, vibration, leakage, altitude etc Test
rig design and fabrication
Legacy conversion Technical documentation
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Mechanical Engineering Software Services
Engineering software PDM/PLM
Engineering Software
PDM/PLM
Process Automation
CAD CAE Customization
Implementation
Customization
Business Process Study GAP Analysis Process
Reengineering Change Management Installation
Staging User Training Support Maintenance
Data modeling GUI Custom reports
Object extensions Custom reports Additional
functionalities Interface development
Macro development Manufacturing Systems (Shop
Floor Control)
Integrations with Enterprise Systems Building
Interfaces to CAD/CAE
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Mechanical Engineering Tools
Unigraphics Pro/E CATIA AutoCAD
Ideas Solid Works CCDraft Alias CADDS
Engineering
Ansys Nastran Abaqus LS Dyna
Ideas Fluent Flotherm Flotran
Hypermesh Moldflow ProMechanica Adams
Analysis
Arbortext Interleaf Frame maker Micrografx
Documentation
Metaphase Windchill eMatrix
ENOVIA/Smart team IMAN
Team center Intralink
PDM/PLM
UG Master CAM
Ideas Catia
Tebis CIM Pro
CAM Tools
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Overview of Services Of Interest to Caran
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Catia expertise
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Catia expertise
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Mechanical Design

• Part Modeling
• 3D fully Parametric feature based design with
  feature tree in excess of 1000 features
• Advanced surfaces (Parametric, CLASS A)
• Use of Hybrid solids, best of both worlds. Ease
  of solids, complexity and flexibility of surfaces
• Styling for Aesthetic / Organic design
• Part families - Design tables and part
  configurations
• Plastics, Casting, Forging, Fabrication
• Assemblies
• Constraint based assembly design
• Large assembly management

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Mechanical Design

• Other expertise
• 3D Functional tolerancing annotation
• Geometry Analysis Curvature, fillets, drafts
• Process Centric Approach to design models
• Library / catalogue creation for standard parts,
  UDF (Power copy)
• Custom tool / application development

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Simulation - Digital Mock up

• Digital walk through and fly through with gravity
  effect
• Simulate motion with speed and acceleration
  measurement and assembly and disassembly features
  for product assembly and maintenance
• Interference analysis, clash detection with
  penetration depth calculation, advanced
  sectioning and measurement
• Swept volume calculations with CGR export

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Simulation - Structural Analysis

• Meshing
• Generative meshing (associative)
• Automatic geometry simplification (Holes,
  fillets)
• Mesh quality analysis Taper, distortion, warp
  factor, skew angle, shape factor etc.
• Generative Assembly analysis with face to face,
  welding point, bolt tightening, contact, fastened
  rigid and spring connections
• External solver interface

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Other Services

• Mold Tooling
• Core Cavity Design
• Mold modeling kinematics
• Draft Analysis on components
• Harness Design
• Creation of bundle segments using construction
  points and use of segment parameters and segment
  route constraints
• Support
• Training, CATIA Deployment support, Design support

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Representative Project Profiles
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Design of Airbag Cover
Project Summary

• Product design optimization for automobile
  airbag cover
• Design and optimization of ribs
• Incorporation of ribs at functional weak points
  to increase stiffness
• Reducing the weight without sacrificing stiffness
  by addition and optimal placement of ribs
• Incorporation of the proposed rib geometry in
  line with the existing tooling
• Creation of class A surfaces complex corner
  geometry where more than 3 varying fillets merge
• Reuse of the existing tooling with minor
  modifications

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Reverse Engineering of Cinch Actuator
Project Summary

• Reverse engineering of cinch actuator (door
  latch)
• Measurement using CMM, profile projectors, gear
  verniers etc
• Material analysis
• Calculation of gear tooth details to match the
  exact profile with correction
• CAD model created in CATIA V5
• Interference check with mating parts
• Manufacturing drawings with GDT

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Migration Catia V4 To Unigraphics
Project Summary

• Translation of Auxiliary Power Unit (APU) model
  from CATIA V4 to Unigraphics
• Huge file size
• Assembly tree recreated
• Minimized data loss
• Fixed topological failure and recreated
  functional features
• Model properties (layers, filters) maintained in
  the translated model
• Geometry check done to achive error free data

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Migration Catia V4 to V5
Project Brief

• To translate a project database of v4 (v4.2.2)
  models to v5 (R 9) as part of the clients
  standardization program on v5
• Creation of migration standards and guidelines
• Minimal data loss
• Fixed topological operation failure Recreated
  functional features (egholes)
• Optimized target models memory size
• Error free and editable v5 model

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Analysis Profiles
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Thermal Stress Analysis of Piston
FEA Model
Project Summary

• Stress and thermal analysis of piston of an
  automotive engine
• Creation of one half of the model along vertical
  axis due to symmetry
• Meshed with tetrahedral elements in Hypermesh
  imported to Ansys
• Creation of surface to surface contact elements
  between piston,crank pin and connecting rod
  using contact elements.
• Induced thermal stresses well within yield stress
  of the material
• Obtained deflection within the specified limits

Von Misses
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FE Analysis of Door Module
Project Summary

• Inputs
• Part Geometry of 9 components constituting the
  door module. CAD models were in VDA format
• Material properties of sheet metal and
  polypropylene parts
• Import VDA data into UG
• Geometry simplification - delete insignificant
  features, extending edges
• Geometry clean-up(deleting extra surfaces,
  overlaps)
• De-featuring features and approximating geometry
• Use of solid elements ( e.g for the magnet
  portion of the speaker)

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FE Analysis of Door Module
Project Summary

• Parts assembled and connectivity checked with
  equivalencing operations and visual verification
  of normals.
• Analysis in MSC Nastran
• Challenges
• Achieving the uniform size specified by the
  client (unknown load case, overlap, dbl thk)
• Minimizing trias to 1-2 in all parts including
  transition areas
• Obtaining an overall good mesh in terms of
  quality which includes warpage, skew, taper and
  jacobian ratio

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Stress Analysis of Transmission Shaft
Project Summary

• Stress analysis of an automotive transmission
  shaft
• Surface effect elements Surf154 was used to apply
  the tangential torque load on the surface of the
  shaft
• Loads were simulated using three bearing supports
  are provided from left to right and the right end
  was fixed to simulate the worst loading condition
• Stress analysis showed a high value of stress at
  the right end of the shaft where the shaft and
  spline meets.
• Maximum stress generated was in the region of
  keyways and spline shaft.
• Stress was high because of the sharp edges at
  splines and suggestions were made to modify the
  manufacturing process of key ways was fine to
  remove sharp edges.

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FE Modeling and Analysis of Gearbox
Project Brief

• Modeling and analysis of gearbox
• Fully parametric model of complex geometry
• Created in UG
• FE Modeling done in Hyper Mesh
• 10 noded Tetrahedron elements
• Around 500,000 elements
• Element size 0.05 at critical locations
• No warning/error element in ANSYS database
• Static analysis for G Loads

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Thank You