FULL VEHICLE BENCHMARKING

Problem Definition

To Compare the physical Vibration test results and arrive at a Finite Element Model which matches the Physical test results. Using this as reference, the customer wants to run reliable tests using the simulation technique. The main requirement is the achieve complete NVH analysis of the BIW along with the cross-members. This would include a variety of different steps such as 3D scanning, reverse engineering, vibration testing, CAE analysis, material testing, obtaining data regarding the mechanical properties of each part after material testing, and finally BOM has to be prepared.

Scope of work

The Scope of work that we had accepted includes
•Full Vehicle Teardown & Teardown documentation
•Stagewise 3D Scanning with necessary referencing for part level scanning & alignment.
•Creation of Level wise Bill of Materials to correlate sub assembly modeling & Assembly documentation, Material composition analysis & Grade identification, Suggestion of Alternatematerials, Correlation of Grade physical properties with actually measured properties on critical parts.

Tools Used for specific activities

The tools used during this process were :

1.COMET L3D blue light scanner : Scanning is the process of capturing a multiple number ofpoints from the surface of the part and forming point cloud data which later after processing is used asan STL file to do reverse engineering(CAD modeling).
2.Geomagic Design-X 3D software : This software is used for reverse engineering. With the help ofthis software a cad model is prepared from the STL file.
3.Solid Works : This software is used for assembly alignment.
4.Mechanical tools such as grinding machine, drilling machine, gas cutter, hammer, chisel, etc.
5.Vibration testing equipment kit.
6.Spectrometer : This machine is used for material testing(chemical composition).
7.Universal Testing Machine : This machine is used to obtain the value for tensile strength, yieldstrength, and elongation.
8.Total Materia : This tool is used to obtained the grade of the material according to their chemicalcomposition as well as the mechanical properties of the material.

Procedure

1. 3D scanning of car in assembly position

The first step of this project is 3D scanning which involves a series of steps such as:
• Cleaning of the car.
• Pasting target stickers on the surface of the car, which are used as references for scanning.

   

• After sticker pasting is done, white powder is sprayed on the car which aids in the scanning of the surface of the car.

  

• Then the scanning of the full car is done.

 

                                     




                                                                                      

2. Tear Down

• After the scanning of the full car in assembly position, the car was torn down to BIW level. Once again, it has to be scanned in BIW condition with cross members.

3. Scanning of BIW with cross members

• Next, the scanning is done for BIW with cross members. This is done for the inner surface, the outer surface, and the underbody surface of the car.

4. Scanning of BIW without cross members

• The area which is covered by cross-members and not scanned is now scanned after the removal of the cross-members. This completes the scanning of the BIW in assembly position.

5. Scanning of individual cross-members

• When the cross-members are removed from the assembly they are not fully scanned. This way, each cross-member can get scanned individually after it gets removed from the BIW.

6. NVH testing

• Actual NVH testing is performed to authenticate the accuracy of the simulation results.

7. Tear down of BIW to individual parts

• After the BIW and cross-members were completely scanned, the BIW and each of the cross-members were torn down into individual parts.
• While removing each individual part the thickness, weight, and different types of weldments (spot weld(2T &3T), laser weld, arc weld and plug weld) is noted down for each part.
• BIW parts are segregated into seven different sub-assemblies which are :
Side outer LHS panel assembly, Side outer RHS panel assembly, Roof assembly, Dash and Cowl panel assembly, Rear panel assembly, Floor assembly and Engine compartment assembly.
• Cross-members are segregated into five different sub-assemblies :
Front bumper guard assembly, Rear bumper guard assembly, Front suspension cross-member assembly, Rear suspension cross-member assembly, and Instrument panel assembly.

8. Scanning of individual parts

• The individual part that gets dismantled from the BIW or cross-members assembly. The individual part then gets scanned which aids us in individual part modeling.

9. Cad modeling

• BIW cad modeling is done assembly-wise such that all the parts and sub-assemblies are perfectly assembled considering the actual thicknesses and the thickness directions.
• All the parts are model and it is shown bellow as outer panels, inner panels and underbody panels which also includes floor panels. Similar to BIW, cross-members also get modeled taking care of all the procedure followed in modeling during BIW.
• All the five cross-members are modeled and shown below :

10. Material testing

• Material testing is done for getting the chemical composition for all the individual parts of BIW and cross-members. The machine used for getting chemical composition is Spectrometer.
• With the chemical composition the materials is segregate into different grades. This is done with the help of a tool called “Total Materia”.
• During the process of Material analysis, we identified thirty different grades in this vehicle.

11. Tensile testing

• Tensile testing is done to get the tensile strength, yield strength and elongation percentage.
• Tensile testing is done for each grade and the machine used to do this is Universal Testing Machine.

Product Benchmarking - An Introduction

Product Benchmarking

Product Benchmarking is the process of comparison & documentation of similar products of different manufacturers / Models with respect to a reference on various factors that affect the user experience of the product.
Some of the factors considered relate directly to the cost of the product, some other relate to the aesthetics & Ergonomics of the product while some relate to the function & performance of the product. However, all of these factors integrate seamlessly to realize one successful product which stands apart from the crowd.
Akuva Infotech is extremely well aligned and geared up to this activity of product benchmarking in a systematic, cost effective & professional manner with years of experience. A direct implication of this is the activity of product optimization and value engineering of the product. Cost Accounting, obsolescence management, Engineering Change management all form part of the post benchmarking activities.

Factors that affect the cost and in turn processes used in Benchmarking are :

1. Inventory Benchmarking This is the total number of individual parts the product comprises of. This is performed to identify the total number of parts, purchasing efforts, cost of records maintenance, cost of maintenance, cost of spares maintenance & cost of repair or replacement and thus directly affects the overall cost of the product pre sale & post sale.

2. Level wise Bill of Materials This is maintained to document the total number of parts, sub assemblies and assemblies in a product. While this gives the total inventory of the product, it also much more insight about the product itself. It also gives an insight into the assembly process, manufactured items, bought out items and standard parts that go into the manufacture of the product.

3. Geometry Benchmarking This is mostly performed for manufactured parts. The complete detailed geometry of the part is understood and benchmarked to understand the process of manufacture and to understand the tell tale process marks, the dimensions of the features, the design intent of the part itself & the purpose of the part functioning in tandem with other parts in the assembly.

4. Material Analysis & Benchmarking An critical part of the product design process is the selection of the correct material for the function. But in a product already manufactured, we would have to identify the material, identify the grade of the material, any heat treatment process, surface finishing or coating on the part. This involves a very important part of the benchmarking process as the material is one of the most cost intensive part of the product.

5. Process Benchmarking An important step in the process of benchmarking, in case of a part, the process of manufacture of the part is to be captured, and documented in a step by step approach. In case of an assembly, the process of assembly of the sub assembly involving parts only or parts & other sub assemblies and the final assembly is to be understood & documented. What is important here is also to factor for all the other tools, jigs & Fixtures, assembly fixtures etc., that are to be used to achieve the final product.

Factors that affect the visual appeal, aesthetics & Ergonomics and in turn steps used in Bench marking are :

1. Aesthetic / Visual Appeal This being an important factor, the correct blend of the overall product design is considered. The Shape, the color scheme, the subtleties all gel together to give out a great product. But how to know whether this is all the things concerned above? This is to undergo extensive market research, Expert analysis, Feedback analytics and design iterations.

2. Ergonomics and User Interaction A lot of planning needs to go into the design of a product to ensure that the user has a comfortable experience using this. The learning curve should be as less as possible, like a fish taking to water. Finally, the ease with which an user adapts to a new product speaks a lot about the success of the product as a whole.

Factors considered in Bench marking pertaining to function & performance include :

1. Product Life Cycle This relates to the total life cycle of the product from the time its conceptualized till it is obsolete. There are different studies that cater to the product life cycle and its management.

2. Performance & Efficiency Depending on the product, performance and efficiency tests are to be performed to improve the user acceptance of the product. It may be due to statutory or mandatory disclosure or even due to suitable promotion of the product, these need to be defined and have to be benchmarked against. Also included in these performance tests may be Noise, Vibration & Harshness tests, endurance tests, impact and other usability tests etc.

Akuva Infotech Pvt. Ltd., a leading Engineering services provider based in Bangalore, India has launched 3DPIndia.com, an innovative platform to support users to get 3D Prints and other processes executed at never before turnaround times.

A unique concept in the already competitive business of 3D Printing services, 3DPIndia.com has unique features that sets this apart from most other websites. Built from scratch, it addresses most of the industry issues about 3D Printing and rapid prototyping.

With more than 15 unique service options, we ensure that the necessary quality is achieved while keeping costs to customers low.

As of now we 

1. allow users to upload custom parts and we print them using multiple technologies
• FDM Method - Fused Deposition Modeling Method
• SLS Method - Selective Laser Sintering Method
• SLA Method - Stereo Lithography Method
• DMLS - Direct Metal Laser Sintering Method
• Also supported is Vacuum casting for multiple parts
• Sheet Metal Prototypes
• MAchined Prototypes
2.  We have a host of ready products that can be purchased directly of the store
• Gadgets
• Accessories
• Toys
• Jewelry
• Collectibles
• Scaled models etc.
3.  For the tech enthusiast we also have 3D Printers available for sale.
• Range of entry level 3D Printers
• Variety of Mid Range & Professional Printers
• High End Production quality printers
• If you are interested in setting up a business for yourself, Do consult us and we will tailor make a suitable enterprise for your budget.
4. We have felt the difficulty to obtain quality raw material in time for our printers. So we went ahead and made quality material available on our website for you to buy.
1. Quick Shipping, 
2. Extensive range
3. Economical pricing make our material options too juicy to let it pass. Do contact us today to know more about our offerings.

  Visit our website 3DPIndia.com  or  akuva.com to know more aobut us.

Best Regards
Vijayasimha SK

Akuva Infotech is now ISO 9001-2008 certified.

Akuva Infotech is now awarded the ISO 9001-2008 certificate for the services they provide in Design & Inspection services of Mechanical Engineering products.

The company has implemented well established and time tested systems for varied activities including 

• New Product Design & Development
• 3D Laser Scanning and Reverse Engineering
• Contact and non contact type inspection services.

Do visit their website at www.akuva.com to know more about the services they offer.

Contact : Vijayasimha SK at 9986508140