MECHANICAL DESIGN AND ANALYSIS

  • Overview
  • Services Offered
  • Research & Dev.
  • Processes & Practices
  • Advantages
  • Tools
  • Case Study

In today’s world organizations have a compelling challenge to continuously innovate and come up with products and processes that give a competitive edge in the crowded market place. An organization can beat this challenge by having a set up which houses a broad spectrum of expertise in various verticals. Mechanical Centre Of Excellence [MCOE] at DSI is one of its kind, a set up, that is striving continuously to add greater value to the stake holders. Leaders with vision, extensive knowledge base, motivated and young working minds, unwavering focus on quality and willingness to accept the challenges make up a perfect mix that house a multi competency service center like MCOE. MCOE at DSI has now become a global competency center offering the best solutions to its customers. MCOE at DSI is involved in numerous projects related to Aerospace, Automobile, Oil hydraulics, Machine Tool, Heavy Engineering, Refrigeration, Rapid prototyping, Tool Design, Water hydraulics and NC Coding-CAM.

                      
MCOE Service Offerings

Product Design
  • Hydraulic Actuator design-Aerospace & Heavy equipments
  • Design of Refrigerated display cases and walk-in-coolers and walk-in-freezers
  • Reverse engineering
  • Fluid film bearing detail design
  • Fluid transfer devices and transmission assembly detail design
  • Press tool detail design for sheet metal parts

Mechanical Engineering Analysis
  • Finite Element Analysis (FEA)
  • Fatigue Life estimation of structural components
  • FEA results calibration with experiments
  • Heat transfer and thermal analysis
  • Computational Fluid Dynamics (CFD) simulations

Design Support Services
  • 3D modeling of components and sub-assemblies
  • 2D to 3D conversion
  • Creating manufacturing drawings and BOM
  • Detailed design of the concept

Manufacturing Engineering Services
  • NC Code and Tool path generation for turning & milling operations
  • Laser path generation for laser machining
  • Creating tool list for Computer aided manufacturing
  • Fixture design & tooling layout

Other Support Services
  • Implementation of Product Data Management module at multiple customer sites

Research and Development

Life estimation of structural components using Strain based fatigue methodologies. Research pertaining to the methodologies required to estimate the life of a component has been developed. Experimental validation of methodologies is to be done. Further there is an objective to develop an object oriented strain based life estimation tool

Design modification of Automotive Camshaft lobe profile design to influence the power and torque generation over the RPM range. As a part of this project, DSI is also developing a Motion Analysis tool to study the kinematics of the cam follower system. The tool being developed is in testing phase.

Processes and Practices

At DSI_MCOE there is an unwavering focus laid to adopt the best practices and develop robust processes to provide high quality deliverables and customer satisfaction. We believe in the philosophy of continuous improvement, hence a metrics based system PMM [Performance Maturity Metrics] has been developed.

Offshore engineering design, far from Head Office or manufacturing site, requires robust and mature offshore processes for transparent project management, effective communication and process reviews to ensure high quality and 100% adherence to timelines consistently. MCOE set up provides all the above said to handle any kind of mechanical engineering design work. The rigorous mile stone review process is in place to maintain consistently quality deliverables to the customers. At MCOE greater emphasis is laid to maintain a strong bridge of communication with customers to capture their expectations and build a strong relationship of trust. All the processes are integrated into the PMM database to regularly measure the progress made on the maturity indices of the processes.

MCOE Advantages

Rapid knowledge dissemination and application

The MCOE structure aimed at providing the opportunity for sharing employee’s critical existing knowledge, lessons learnt, best practices and expertise is shared among the stake holders. Hence, there will be collaborative knowledge sharing happens across the product domains and software.


Compressed product and process life cycles

The product life cycles have significantly shortened, compressing the available window for recouping development for expenses. Hence, the complex and often irreversible design decisions need to be made quickly and accurately; MCOE knowledge management can provide to facilitate this. Diverse expertise is integrated to innovate Brainstorming, strategy planning, proactive action etc need collaboration, often across multiple product groups. Thus MCOE develops process competence, resulting in time-to-market and cost reduction.

  • Case Study 1: CFD Analysis of Aerators

    Objective: Performance comparison of Aerators

    Results and Benefits:

    • Performance analysis of two different products were compared in terms of air flow behavior (velocity and pressure drops for the entire assembly as well as at the desired locations )
    • Based on the analysis result, customer can choose the appropriate models for their practical application from different models available in the market and suggestion can be made for customized models

  • Case Study 2: Optimization of Fan basket

    Objective: Design optimization of Fan basket design aimed at change of material

    Results and Benefits:

    • Full Ownership of new design
    • Elimination of metal fan basket
    • Better performance & Noise properties with Plastic fan Basket.
    • Cost reduction (145gms –finished component weight)
    • Ease to manufacture & assemble the part

  • Case Study 3: Development of Motion analysis tool [R & D project]

    Objective: To Develop a MS Excel based tool to analyze the kinematics of the Cam-Follower system, further to modify the cam profile to develop a new cam lobe using the same tool

    Results and Benefits:

    • Tool is simple, easy to use and quick
    • Tailor made for the reverse engineering approach
    • Gives all the required plots in comparison to available commercial packages
    • Saving on the license cost of commercial packages