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Case Studies

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Case Study I: - Oil Sumps for Engines
This Case study gives an insight on how the part design can be simplified by optimization in virtual tryout / simulation. Oil sumps of various Tata Motors projects were made feasible using virtual tryout tools. The learning from these exercises were documented to enable product designers to design oil-sumps to engine requirements in shortest possible virtual tryout loops.
The exercise made possible Implementation of 3-Ply Sandwich material for special NVH (Noise, Vibrations and Harshness) application in one of the Oil Sumps.

Virtual Tryout Tools
Case Study II: - Head Lamp Cover for a Tata Mini Truck
Initial Head lamp cover was made up of 2 stamping parts joined by spot welding. Due to number of joints the head lamps cover was prone to leakages. After studying various possible solutions a cost-effective, single piece design had been proposed and implemented successfully.

Stamping Parts Joined by Spot Welding
Substantial savings in tooling cost, sheet material, welding was recorded.
Case Study III: Simultaneous Engineering for Manufacturing Feasibility
As per the Simultaneous Engineering concept, all design activities should occur simultaneously, the overall goal being that the concurrent nature of these processes significantly reduces project implementation time while increasing productivity and product quality. The success of Simultaneous Engineering lies in allowing errors and redesigns to be discovered early during the design process when the project is still in a more abstract and digital realm. By locating and fixing these issues early, the design team can avoid costly errors as the project moves to more complicated computational models and eventually into the physical realm.

Simultaneous Engineering for Manufacturing Feasibility
Case Study IV: Dimensional Variation Analysis (DVA) of Using 3DCS Software on
CATIA V5 R19 Platform
Dimensional Variation Analysis helps in closing the gap between engineering investigation and manufacturing quality assurance. The challenge is to integrate such components without experiencing significant production problems so as to reduce costs and deliver products in the market faster and better. By leveraging the advantages of 3DCS CatiaV5, variation analysis, reduction of assembly flow time and recurring costs resulting from rework and adjustments late in the production cycle can be achieved.

Dimensional Variation Analysis of Using 3DCS Software
DVA report from 3DCS for Tailgate Complete of a Tata Crossover