ARUNKUMAR S
Research & Development
Sundaram Auto Components Limited
Sundaram Auto Components Limited which is part of the $8.5 billion TVS group, started its operations in 1988. Since its inception, they have grown to a full-service provider of injection molded plastic solutions to the automotive industry.
They strongly believe in the growth philosophy – of “Being the first choice for all stakeholders”. They achieve this through their passion for automobiles and continual endeavour to use plastic as a medium to provide innovative solutions to meet the requirements of automobiles. They can achieve this through their experience gained over 25 years in developing plastic parts and solutions for automobiles and establishing seamless integration of processes from design, and engineering to manufacturing ensuring that best practices are deployed across locations.
Operating from 5 locations – Hosur, Chennai, Nalagarh, Mysore, Bhiwadi, and Sanand, they cater to a diversified portfolio, designing and manufacturing products for two-wheeler, commercial vehicle, passenger vehicle and three-wheeler segments in the automotive industry. Their focus is on value-added products, services, and innovative solutions to enhance the quality, and reliability and provide the best value proposition to their customers. To ensure this focus, they practice Total Quality Management (TQM) at all levels.
Sundaram Auto Components Limited is a specialist in the development and manufacture of best-in-class plastic components and assemblies for different application areas in the automotive segment.
Challenge
Sundaram Auto Components Limited decided to take up the responsibility of developing a Class “B” surface and create “Design for Manufacturing” for their development team by taking the Class “A” surface generated by the OEMs as input.
The process of conversion includes a method where the input Class “A” surface first must be repaired by filling all the gaps. Then offset the Class “A” surface and use surface commands like sweep, extend, trim, etc. to create a Class “B” surface and use the thickness option to create a solid part.
Once the solid part is created, they need to modify the solid part to optimize for “Design for manufacturing” and share it with their Manufacturing team.
They quickly realized that the Surface design activity could not be accomplished with the Design software they were presently using.
Solution
The company decided to use Dassault Systemes’ CATIA V5 MD2 license for the Class “B” surface creation development activity and optimize the solid part for “Design to Manufacturing”. For the creation of a Class “B” surface from the input file shared by OEM, initially, it would take around 5-6 hrs and still they were unable to get the surface finish as per requirement.
The Design team approached the Altem technical team to achieve the Class “B” surface by offsetting the input Class “A” surface in a quick and efficient manner. We understood that OEMs were using ALIAS software for Class “A” surface creation. When we checked the settings in the ALIAS software, OEM had configured their ALIAS settings as per NX and we shared them few documents and requested them to change the settings in the ALIAS software as per the CATIA V5 requirements. Now the Class “A” surface is generated with the new settings in ALIAS, the Sundaram Auto Components design team was able to create a Class “B” surface in 15-20 minutes with an excellent surface finish.
The surface design workbench in CATIA V5 is a powerful tool for creating complex and organic shapes that cannot be easily achieved with traditional solid modeling techniques. It allows designers to create and manipulate surfaces in 3D space, using a variety of tools and techniques to achieve their desired results.
The surface design workbench allows designers to create and edit curves in 3D space. This includes tools for creating splines, arcs, and other types of curves that can be used as the basis for surface creation. With the surface design workbench, designers can create complex surfaces that follow the contours of their curves. This includes tools for creating lofted surfaces, swept surfaces, and more. Once surfaces have been created, designers can use the surface design workbench to modify them in a variety of ways. This includes tools for trimming, extending, and blending surfaces together to create complex shapes. The surface design workbench also includes tools for analyzing the geometry of surfaces and optimizing them for specific applications. This includes tools for checking surface continuity, curvature analysis, and more.
Altem Technologies is a valuable partner of Dassault Systems India Pvt Ltd to provide Dassault Systems solutions to valuable customers like Sundaram Auto components and provide technical support throughout the design process of the products with the help and guidance of the Dassault Bangalore team. Dassault Systems India is providing solutions that meet the expectations of the Sundaram Auto Components team to overcome their challenges.
Benefits
With the right settings in ALIAS software by the OEM, they can share the Class “A” surface which can be imported into CATIA V5 software by the Sundaram Auto Component’s Design team. They can fill the gaps in the Class “A” surface, offset it, and create the Class “B” surface within 15-20 minutes using the various tools available IN the CATIA Surface design workbench.
Once the Class “B” surface is created, they will use the “thickness” option and create a solid part. Then the Solid part is optimized for “Design for Manufacturing”, and they can share it with the Manufacturing team for the next process.
Since this entire process can be now completed within a couple of hours which was taking considerably more time in the previous situation, the design team can handle the design work of many more components and their productivity has increased.
Now Sundaram Auto Components team is looking to take up more responsibilities in Design work and continue to grow their expertise and value soon which is in line with their philosophy of “Being the first choice for all stakeholders”.
Publication Date : February, 2023
About Altem Technologies Pvt. Ltd
Altem Technologies is a well-established 3D digital experience company that has been actively contributing to the industry for nearly 15 years. Initially rooted in PLM software and 3D Printing (representing Dassault Systemes India Pvt Ltd and Stratasys India respectively), Altem has successfully transformed into a prominent provider of comprehensive 3D digital solutions. Altem’s 3D Innovation platform offers an extensive array of products catering to various applications, including design, reverse engineering process, asset digitization, prototype manufacturing, life science, healthcare, culture and heritage, and consultancy services, among others. Altem with a diverse clientele spanning automotive, aerospace, manufacturing, healthcare, research academia, and more, Altem adeptly addresses the unique requirements of each industry through a combination of expertise and innovation. Our team comprises skilled professionals, including Scientists, Application Engineers, Designers, domain experts, and software specialists, all working collectively to deliver exceptional solutions to our valued customers.
Altem Technologies Pvt Ltd, besides being a major provider of 3D Scanning services in India, is also a leading provider of 3D Printing Services in India with 3D Printing technologies like FDM, Polyjet, DLP, Metal, etc. Altem offers a complete solution around 3D Digitization and Innovation and has emerged as a one-stop-shop for all 3D Printing, 3D Scanning, CAE, PLM, and Life Science needs, offering a wide spectrum of products for engineering and life sciences companies in India.
