Converting Design To Prototype

Converting Design to Prototype
Author: Preetam Singh (9728428168, preetams844@gmail.com )
OBJECTIVE-
The main objective is to cop-up the changes occur from design to manufacturing. Secondary
objective is to validate the design in respect to physical model.
INTRODUCTION:-
A lot of changes occur during manufacturing due to process included in manufacturing. Due
to these processes, dimension and tolerance changes occur and also bring unwanted issues
with clearance of frame. These changes lead to incur the bigger changes in the performance of
the final vehicle which affects the overall result in the competition
Points to be taken care of while designing-

A.) Tolerances –
This is a very critical parameter to be taken into consideration as it plays a major role in
performance. It is necessary that the dimensions, shape and mutual position of surfaces of
individual parts are kept within a certain accuracy to achieve their correct and reliable
functioning. Dimensional and geometric property tolerances are to be provided by the designer
keeping in mind the functional requirement of the part and also on the limitations of the
manufacturing process, tooling and machine used, and the planned cost of the part. Parts
modelled on 3D software contain features with basic dimensions. Critical dimensional tolerances,
geometric properties and surface roughness tolerances have to be specified in 2D drawings.
Designs require Assembly of two parts to provide a Fit which performs an intended function –
location or movement with respect to each other.
Fits can be classified as

a) clearances fit
b) transition fit
c) interference fit
In selecting the proper fit, careful consideration should be given to bearing operating conditions.
Major specific considerations are:
 Load characteristics and magnitude

 Temperature distribution in operating
 Bearing internal clearance
 Surface finish, material and thickness of shaft and housing
 Necessity to compensate for shaft thermal expansion at the fitting surface
 Bearing type and size
effi.saenis.org Drive the Future Page 1 of 4

In Effi-cycle, some places where fits is needed e.g. – Intermediate shaft with bearing,
Intermediate shaft with sprocket, steering column, Motor shaft and sprocket etc.
B). Welding-
1.) The type of welding plays a crucial role w.r.t to material used for chassis. As fabrication
point of view, 3 types of welding can be available at your college level i.e. 1. Arc welding
2. MIG welding 3. TIG welding.
2.) The very first, Arc welding doesn’t go good now-a-days because of carbon % in the AISI
grades. Also it does not have enough strength by taking the experience level of student
into consideration.
3.) Second is, MIG welding which is basically used more till the common grade AISI 1018
And AISI 1020. As the carbon and chromium % suits the MIG welding. Factor taken into
consideration is carbon gas, ER70S6 filler material and the feeding system of MIG
Welding.
4.) Third one is, TIG Welding, highly recommended for AISI 4130 grade. As most of the
teams are moving towards AISI4130 Grade for better strength to weight ratio. Filler
material used for this welding is ER70S2, which has 3 de-oxidizer (Search them), helps to
control the oxidation of rich carbon %.
C) Welding with Fixtures-

Every material has a tendency to shrink at the time of cooling. This will result in deformation
of shape and dimension. The same happens at the time of welding which lead to dimensional
changes in frames as well as suspension links. This deformation affects the performance of
vehicle as well as maintaining the clearance of driver body with different frame members.
Introducing the fixture at time of welding will minimize the changes occurred during
manufacturing. The manufactured model should be dimensionally accurate w.r.t. designed
model. A normal fixture will hold the tubes and channels in the same position till the material
cool down which will minimize the dimensional changes due to shrinkage.
Though using the fixture will lead to introduce unwanted residual stress near to the Heat
Affect Zone (HAZ) but this factor can be ignored as the wall thickness is less than 5mm. Some
picture shown below are for Fixtures for welding the frame.
Fixture type for suspension link Fixture type for Frame

D) DFMEA -
DFMEA is Design Failure Mode and Effect Analysis which is needed to identify the mode of
failure of any component and its effect on the component or the vehicle in whole. After that,
severity of the failure mode and its occurrence level is determined. All three of above
parameter will be given ratings from 1 to 10. Then a cumulative rating is given for the Risk
associated with that failure mode which is called RPN.
RPN = (Severity Rating) × (Occurrence rating) × ( Detection rating)
Various compoent
of vehicle
Identify identify failure identifyfaiilure

failure efffect mode causes
Severity Detection Occurence
RPN
Preventive
Measures
Conclusion
 Now if we are using OEM parts then DFMEA is not required as the OEM itself releases
the part in market after DFMEA and DVP. Only if we are changing the OEM part to fit
it in our design, then only DFMEA is required.
E) DVP&R-
DVP&R is Design Validation Plan and Report. It is simply a tool in form of a document which
gives data of a product, is it meeting with its design specification and performance? As every
year, we change the design of vehicle and components then it is required to validate the new
design. It is closely associated with DFMEA. DVP&R is more concentrated upon “How” we are
going to feed the data to DFMEA?

Structure of a DVP&R- It totally depends upon the team to customize the DVP & DR according
to the teams’s need.
The basic structure contains below:

 Specification / Test Name – name the specification and the name of the test to be performed
(The What)
 Method or Procedure – information about the method or procedure for the test (The How)
 Duration – Indicate the duration of the test or analysis. Duration can be defined by length of
run time, number of cycles, etc.
 Acceptance Criteria – Requirements or conditions that must be met for the product to pass
the test
 Results – In this column report the actual results of the analysis or test
 Test Results Status – Indicate whether the results are Pass or Fail
 Test Completed By – Enter the name of the individual whom performed the test
 Notes or Comments – This column is used for any important details, comments or notes
regarding the execution or results of the test or analysis performed
The DVP format is also given in the Technical Documentation Package released by Technical
Committee. Teams must follow that format for the event purpose.
Links and reference:
[1]. Institute of Health Care Improvement, Cambridge, Massachusetts, USAFMEA Tool

https://asq.org/quality-resources/fmea
[2]. American Society of Quality (ASQ), Failure Modes and Effects Analysis (FMEA)
http://www.ihi.org/resources/Pages/Tools/FailureModesandEffectsAnalysisTool.aspx
[3]. Miller Weldings
https://www.millerwelds.com/
[4] IITK tolerance fit guide
http://home.iitk.ac.in/~anupams/ME251/tolerances_tables.pdf
[5] SKF Bearing selection guideline
https://www.skf.com/group
-Efficycle Alumni Committee
[DISCLAIMER: This document is created by members of Efficycle Alumni Committee based upon some facts and
their experiences of the event. The information included in this document must be considered only as the advice from
alumni for improvement in vehicle design, fabrication and validation. Some or all information may not be suitable for
specific designs developed by efficycle teams. These must NOT be considered as official guidelines & instruction
from Efficycle Technical Committee or the part of rulebook.]

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Converting Design To Prototype

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Converting Design to Prototype

Author: Preetam Singh (9728428168, preetams844@gmail.com )

Points to be taken care of while designing-

Fits can be classified as

 Load characteristics and magnitude

effi.saenis.org Drive the Future Page 1 of 4

C) Welding with Fixtures-

Fixture type for suspension link Fixture type for Frame

effi.saenis.org Drive the Future Page 2 of 4

Identify identify failure identifyfaiilure

Severity Detection Occurence

effi.saenis.org Drive the Future Page 3 of 4

The basic structure contains below:

Links and reference:

[1]. Institute of Health Care Improvement, Cambridge, Massachusetts, USAFMEA Tool

-Efficycle Alumni Committee

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