FULL TIME INTERNSHIP REPORT

ON
PRODUCT DESIGN USING CAD SOFTWARE

CARRIED OUT AT SKILLDZIRE TECHNOLOGIES PRIVATE LIMITED

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY,

ANANTAPURAM.

For the partial fulfilment of the requirement for award of the degree of

BACHELOR OF TECHNOLOGY

IN
MECHANICAL ENGINEERING

Submitted by
G S Akash - 204M1A0331
Under the Esteemed Guidance of
Mr. G. Suresh M.Tech, (Ph.D).,
Associate Professor
DEPARTMENT OF MECHANICAL ENGINEERING

VEMU INSTITUTE OF TECHNOLOGY

(Affiliated to JNTU Ananthapuramu, & Approved by AICTE, New Delhi)

An ISO 9001:2015 Certified Institution P. Kothakota, Chittoor (Dt.) A.P-517112.

 VEMU INSTITUTE OF TECHNOLOGY
(Affiliated to JNTU Ananthapuramu, & Approved by AICTE, New Delhi)

An ISO 9001:2015 Certified Institution and Accredited by NBA, NAAC A+

Tirupathi-Chittoor Highway, P. Kothakota, Chittoor (Dt.) -517112.
ANDHRA PRADESH
2023-2024.

CERTIFICATE
This is to certify that the Full Time Internship Report on “Product Design using CAD
Software” was carried out at Skilldzire Technologies Private Ltd, Hyderabad. Is being
submitted by G S Akash (204M1A0331) in partial fulfillment for the award of the degree of
Bachelor of Technology in MECHANICAL ENGINEERING, Affiliated to the JNTUA,
Ananthapuramu. This record is a bonafide work carried out by him under my guidance and
supervision during the academic year 2023-2024.

INTERNSHIP GUIDE HEAD OF THE DEPARTMENT

Mr. G. Suresh, M.Tech., (Ph.D)., Dr.K.V.N.V.N.RAO, M.Tech., Ph.D.,
Associate Professor Professor & HOD
Department of M.E Department of M.E
 VEMU INSTITUTE OF TECHNOLOGY
P.kothakota, Near Pakala, Puthalapattu (M), Chittoor (Dt.) A.P-517112.
Affiliated to JNTU, Ananthapuramu, Approved by AICTE, New Delhi
ISO 9001:2015 Certified Institution and Accredited by NBA, NAAC A+
2023-2024

DEPARTMENT OF MECHANICAL ENGINEERING

DECLARATION

I hereby declare that Full Time Internship report entitled Product Design using CAD
Software in Skilldzire Technologies Private Ltd., has been done by me under the guidance of
Mr. D. Suresh M.Tech., (Ph.D)., Associate Professor, VEMU INSTITUTE OF TECHNOLOGY,
P.KOTHAKOTA. This work has been submitted to VEMU INSTITUTE OF TECHNOLOGY, P.
KOTHAKOTA, as a part of partial fulfillment for the degree of Graduate in Bachelor of
Technology. I also hereby declare that this Industrial Training report has not been submitted at any
time to any other institute or university for the award of any degree.

G S Akash - 204M1A0331

PLACE: P. KOTHAKOTA
DATE:
 ACKNOWLEDGEMENT

An endeavor over a long period can be successful only with the advice and support of many well-
wishers. I take this opportunity to express my deep gratitude and appreciation to all of those who
encouraged me to successfully complete the Full Time Internship.

I wish to express my heart full thanks and deep sense of gratitude to the honorable Chairman Prof.
K. CHANDRASEKHAR NAIDU GARU, M. Tech, Ph.D., for his encouragement and inspiration
throughout the process.

My special thanks to my principal Dr. NAVEEN KILARI, M. Tech, Ph.D., who has provided
all the required facilities and helped in accomplishing the Internship report within time.

With Profound respect, we express our deep sense of gratitude to our Head of the department and
Professor Dr. K.V.N.V. N RAO, M. Tech, Ph.D., for being the source of inspiration throughout
the study in this course.

I am thankful to my guide and co-ordinator Mr. G. Suresh, M. Tech, (Ph.D)., Professor for his
valuable guidance and efforts throughout the Internship report.

Finally, I would like to extend my deep sense of gratitude to all my peers, Mr. M. SRIKANTH
founder of Skilldzire Technologies Private Ltd, and last but not greatly indebted to my parents
who inspired me at all circumstances.

G S Akash - 204M1A0331
 Program Book Full Time Internship

AP STATE COUNCIL OF HIGHER EDUCATION

(A STATUTORY BODY OF GOVERNMENT OF ANDHRA PRADESH)
 Program Book
For
Full-Time Internship

Name of the Student : G S Akash

Name of the College : Vemu Institute of Technology

Registration Number : 204M1A0331

Period of Internship : Fifteen Weeks

From: To:

Name & Address of the Intern Organization : SkillDzire Technologies Private Limited &
Business Square, HITECH City,
Hyderabad, Telangana-500081
 Full Time Internship Report
On
(Product Design using CAD Software was carried out at Skilldzire
Technologies Private Ltd)
Submitted in accordancewith therequirement for thedegree of B.Tech.

Name of the College : VEMU Institute of Technology

Department : Mechanical Engineering

Name of the Faculty Guide : Mr. G. Suresh

Duration of the Internship : Fifteen weeks

Name of the Student : G S Akash

Programme of Study : B.Tech

Year of Study : IV- Year II Semester

Register Number : 204M1A0331

Date of Submission :
 STUDENT DECLARATION

I G S Akash a student of B.Tech Program Reg. No 204M1A0331 of the Department of Mechanical

Engineering, VEMU Institute of Technology College do hereby Declare that I have completed the
mandatory internship from 05-02-2024 to 15-04-2024 in SkillDzire Technologies Private Ltd under
the Faculty guidance of Mr.G.Suresh., M.Tech, (Ph.D)., Department of MECHANICAL
ENGINEERING

(Signature and Date)

Endorsements

Faculty Guide

Head of the Department

Principal
 LIST OF CONTENTS

S.NO DESCRIPTION PAGE NO

1 Chapter 1 Executive summary 1-2
1.1 Learning outcomes 2
2 Chapter 2 Overview Of The Organization 3-4
2.1 Introduction of the Organization 3
2.2 Vision, Mission, and Values of the Organization 3
2.3 Policy of the Organization, in relation with the intern 3
role
2.4 Roles and responsibilities of the employees in which the 4
intern is placed
2.5 Future Plans of the Organization 4
3 Chapter 3: Internship Part 5
3.1 Activities and Responsibilities 5
3.2 Weekly work schedule 5
3.3 Equipment used 5
3.4 Tasks performed 5
4 Chapter 4: Activity Report 6-44
4.1 Activity log for the 1st week 6
4.2 Week – 1 7-8
4.3 Activity log for the 2nd week 9
4.4 Week – 2 10
4.5 Activity log for the 3rd week 11
4.6 Week – 3 12-13
4.7 Activity log for the 4th week 14
4.8 Week – 4 15
4.9 Activity log for the 5th week 16
4.10 Week – 5 17
4.11 Activity log for the 6th week 18
4.12 Week – 6 19-20
4.13 Activity log for the 7th week 21
4.14 Week –7 22
4.15 Activity log for the 8th week 23
4.16 Week – 8 24-25
4.17 Activity log for the 9th week 26
4.18 Week – 9 27-28
4.19 Activity log for the 10th week 29
4.20 Week – 10 30-31
4.21 Activity log for the 11th week 32
4.22 Week –11 33-34
4.23 Activity log for the 12th week 35
4.24 Week – 12 36-37
4.25 Activity log for the 13th week 38
4.26 Week – 13 39
4.27 Activity log for the 14th week 40
4.28 Week – 14 41-42
4.29 Activity log for the 15th week 43
4.30 Week – 15 44
5 Chapter-5 conclusion 45

LIST OF FIGURES

S.NO DESCRIPTION PAGE NO

1 Product life cycle 8
2 Mechanical design process 13
3 Methodology of DFMA 20
4 Steps in Sand Casting 25
5 Steps in Investment Casting 25
6 Die casting 27
7 Permanent mold casting 28
8 Closed die casting 30
9 Open die forging 31
10 Cold forging 34
11 Sheet metal process 37
12 Sheet metal components 42
13 Plastic components - 3d modeling 44
 CHAPTER 1: EXECUTIVE SUMMARY

“SkillDzire” epitomizes the modern approach to skill development, catering to the multifaceted needs
of individuals and businesses alike. Its extensive repository of courses spans a broad spectrum,
encompassing technical disciplines, soft skills, and specialized domains. Through this diverse
curriculum, SkillDzire empowers learners to adapt to the ever-evolving demands of the contemporary
job market, equipping them with the knowledge and expertise necessary to thrive in their chosen fields.
Whether aspiring professionals seeking to augment their resumes or seasoned veterans aiming to stay
ahead of the curve, SkillDzire provides a platform for continuous learning and growth.

At the core of SkillDzire mission is a dedication to fostering a culture of innovation and excellence.
Through cutting-edge instructional methodologies and curated content, the platform ensures that users
receive high-quality, relevant education that aligns with industry standards and best practices.
Additionally, SkillDzire fosters an interactive learning environment, facilitating collaboration and
knowledge sharing among peers. By leveraging the collective wisdom of its community, SkillDzire
enriches the learning experience, enabling participants to glean insights and perspectives from diverse
backgrounds and expertise.

As the landscape of work undergoes rapid transformation, SkillDzire remains committed to empowering
individuals and organizations with the tools they need to succeed. With a forward-thinking approach
and a relentless pursuit of excellence, SkillDzire serves as a catalyst for personal and professional
growth, guiding learners towards their full potential. Through its comprehensive suite of resources and
unwavering support, SkillDzire continues to shape the future of education, one skill at a time.

1
1.1. LEARNING OUTCOMES:

• Understanding User Needs: Identifying and understanding user preferences and requirements
through research and analysis.

• . Design Thinking: Applying design thinking methodologies to solve problems creatively,

including ideation, prototyping, and testing.

• 3 Technical Skills: Acquiring skills in CAD, 3D modelling, prototyping, and materials selection
for translating concepts into tangible designs.

• Human-Cantered Design: Prioritizing user experience and usability in designs, creating

intuitive and accessible products.

• Visual Communication: Developing skills in sketching, rendering, and design presentations to

effectively communicate design concepts.

• Design Principles: Understanding principles like proportion, balance, contrast, and harmony for
creating aesthetically pleasing and functional designs.

• Prototyping and Testing: Creating prototypes and conducting usability testing to gather
feedback and iterate on designs.

• Collaboration and Teamwork: Working on multidisciplinary projects to develop collaboration

and teamwork skills.

• Ethical and Sustainable Design: Considering ethical and environmental factors such as
sustainability, ethical sourcing, and social responsibility in product design.

• Industry Standards: Ensuring that designs meet industry standards and contribute positively to
society through innovative and user-friendly products

2
 CHAPTER 2: OVERVIEW OF THE ORGANIZATION

2.1 Introduction of the Organization:

SkillDzire is an innovative online platform dedicated to skill development, education, and career
advancement. With a diverse range of courses covering various skills, from technical to soft skills,
SkillDzire caters to the needs of learners across different industries and career paths. Upon completion,
many courses offer certifications that can enhance learners' resumes and career prospects. Additionally,
SkillDzire provides job placement assistance and career support services to help learners find relevant
employment opportunities. The platform offers personalized learning paths tailored to individual
interests, goals, and skill levels, allowing learners to progress at their own pace. With flexibility in
accessing courses and materials, learners can study anytime, anywhere with an internet connection,
making it convenient for working professionals and students alike. SkillDzire also fosters a community
of learners, enabling interaction, collaboration, and support from peers and instructors. Emphasizing
industry relevance, courses on SkillDzire are designed to meet industry standards and demands, ensuring
that learners acquire skills that are in high demand in the job market. Through innovative methodologies
like design thinking and practical project-based learning, SkillDzire encourages creativity and problem-
solving skills. Moreover, the platform promotes ethical and sustainable practices in skill development
and education, emphasizing social responsibility and environmental awareness. Overall, SkillDzire aims
to empower individuals with the knowledge and skills they need to succeed in their careers and make a
positive impact in their communities.

2.2 Vision, Mission and Values of the Organization:

Vision: To make quality education and skill development accessible to all, empowering individuals
to reachtheir full potential and contribute to society.

Mission: SkillDzire provides innovative online learning experiences, bridging the gap between
education and employment through practical skills training, partnerships with industry experts, and
continuous platform improvement.
Values: Excellence, Accessibility, Empowerment, Community, Integrity, Innovation.

2.3 Policy of the Organization, in relation with the intern role:

Data Privacy: SkillDzire maintains strict policies to protect user data and privacy, ensuring compliance
with relevant regulations and standards. We enforce policies to ensure that all educational content meets
high standards of accuracy, relevance, and reliability. SkillDzire upholds ethical standards in content
delivery, including avoiding plagiarism and providing proper attribution. We have clear community
guidelines to promote respectful interactions among users and prevent harassment or discrimination.
SkillDzire is committed to making its platform and content accessible to users of all abilities, including
those with disabilities. We strive to keep our courses and services affordable to ensure that education
3
 remains accessible to everyone. SkillDzire maintains transparency in its operations, including pricing,
policies, and terms of service. We provide channels for users to submit feedback and suggestions,
allowing us to continuously improve our platform and services. SkillDzire implements robust security
measures to protect user accounts, data, and transactions from unauthorized access or breaches. We are
committed to continuously reviewing and updating our policies to adapt to changing needs, technologies,
and regulatory requirements.

2.4 Roles and responsibilities of the employees in which the intern is placed:
Employees are responsible for facilitating the intern's learning and development by providing guidance,
mentorship, and opportunities to apply their skills in real-world scenarios. Employees assign tasks and
projects to interns, ensuring that they gain practical experience and contribute meaningfully to the team's
objectives. Employees supervise the intern's work, providing feedback, direction, and support as needed
to help them succeed in their role. Training. Employees may provide training sessions or resources to
help interns gain specific skills or knowledge relevant to their role or the organization. Employees help
integrate interns into the team and organization by introducing them to key team members, explaining
the company culture, and facilitating networking opportunities. Employees communicate expectations,
deadlines, and feedback clearly and effectively to interns, fostering open and transparent
communication. Employees’ model professionalism and work ethic, setting a positive example for
interns to follow in their conduct and interactions. Employees may involve interns in problem-solving
processes, encouraging them to think critically and contribute ideas to overcome challenges. Employees
may participate in evaluating the intern's performance, providing input for performance reviews and
constructive feedback to support their growth. Employees share their expertise and insights with interns,
helping them learn from their experiences and develop a deeper understanding of their role and industry.

2.5 Future Plans of the Organization:

The organization's future plans include expansion into new markets, diversification of offerings, and
continued innovation. Sustainability is a priority, with a focus on responsible business practices and
environmental initiatives. Talent development and enhancing the customer experience are key
objectives, along with digital transformation to streamline processes and improve efficiency.

4
 CHAPTER 3: INTERNSHIP PART

3.1 Activities and Responsibilities:

• Assisting in product design and development.
• Conducting market research and analysis.
• Creating detailed 3D models of product designs using CAD software.
• Study on different types of production methods
• Participating in cross-functional team meetings.

3.2 Weekly Work Schedule:

• Full-time internship following regular class hours.
• Attending the live webinars conducted by the institution.

3.3 Equipment Used:

• Design software (such as CAD) for product design and modeling.
• 3D Printers are used to create physical prototypes of product designs quickly and cost-effectively
• Quality control tools and equipment for inspections and tests.

3.4 Tasks Performed:

• Assisting in designing and developing automotive components.
• Conducting market research to identify trends and customer needs.
• Supporting manufacturing processes, including assembly and testing.
• Assisting in inventory management and production planning.
• Participating in team meetings, brainstorming sessions, and project collaboration.

5
 CHAPTER 4: ACTIVITY REPORT
4.1 ACTIVITY LOG FOR THE 1st WEEK

PERSON IN
DAY BRIEF DESCRIPTION LEARNING
CHARGE
OUTCOME
OF THE DAILY SIGNATURE

ACTIVITY

The first day focuses on introducing Understanding the concept

Day –1 participants to the Product Development and significance of PDLC
Life Cycle (PDLC) in product development.

Emphasizes the importance of cross Recognizing the value of

functional collaboration cross- functional
Day -2 and interdisciplinary collaborationin product
teamwork in product development. development.

Participants delve into the significance o Learning methods for

Day –3 market research and user feedback in collecting and analyzing use
refining product designs and enhancing feedback to iterate product
market fit. designs.

focuses on the prototyping and testing

stagesof the PDLC. Exploring various
Day –4 prototyping methods, such
as rapid prototyping and 3D
printing.

Participants explore the manufacturing Learning about supply chain

Day –5 and commercialization stages of the management and logistics in
PDLC. product manufacturing.

Participants engage in group discussions Integrating knowledge of

Day –6 and reflection exercises to consolidate thePDLC stages and their
thei learning and identify key takeaways. significance in product
development

6
 WEEKLY REPORT
4.2 WEEK – 1 ( From 8-01-24 To 14-01-24 )

Topic Covered: Product Development Life Cycle

Description:

Week 1 serves as a foundational exploration into the intricate process of product development, focusing
particularly on the Product Development Life Cycle (PDLC). This week is pivotal as it provides participants
with a comprehensive overview of the stages involved in bringing a product from conception to market.

Participants delve into understanding the essence of PDLC, which encompasses a series of steps aimed at
systematically designing, developing, and launching a product that meets market needs and fulfills customer
expectations. Through interactive lectures, case studies, and real-world examples, students gain insights into
each stage of the PDLC, understanding its significance and the activities involved at every step. The week
begins byintroducing the concept of PDLC, emphasizing its role as a structured framework that guides product
development activities. Participants explore the various stages typically included in the PDLC, such as
ideation, conceptualization, design, prototyping, testing, manufacturing, and commercialization. Moreover,
students learn about the importance of cross-functional collaboration and interdisciplinary teamwork
throughout the product development journey. They gain an appreciation for the diverse skill sets and expertise
required at different stages of the PDLC, highlighting the collaborative nature of product development
initiatives. Furthermore, the week provides an opportunity for participants to grasp the significance of market
research, user feedback, and iteration in refining product designs and enhancing market fit. By understanding
customer needs and preferences, participants can effectively tailor their product development strategies to
address specific market demands and capitalize on emerging opportunities.

In essence, Week 1 sets the stage for a holistic understanding of product development, laying the groundwork
for participants to navigate the complexities of the PDLC with clarity, purpose, and strategic foresight.
Through a blend of theoretical knowledge and practical insights, students are equipped to embark on a
transformative journey into the dynamic world of product innovation and development.

7
Fig.1. Product Life Cycle

8
 4.3 ACTIVITY LOG FOR THE 2nd WEEK

BRIEF DESCRIPTION OF LEARNING PERSON IN

DAY
THE DAILY ACTIVITY OUTCOME CHARGE
SIGNATURE

Understanding the concept and

significance of the Product Life
Day –1 Introduction to Product Life Cycle (PLC) Cycle (PLC) in product
management.

The strategies applicable at each stage of Exploring strategies for

Day -2 maximizing profitability and
the Product Life Cycle (PLC).
market success at each stage.

Participants delve into the factors Analyzing the influence of

Day –3 influencing the trajectory of the Product competitive forces on product
LifeCycle (PLC). lifecycle stages.

Exploring strategies for

Day –4 Focuses on product portfolio allocating resources across
management within the context of the products with different life
PLC. cyclestages.

The concepts learned throughout the Integrating knowledge of the

Day –5 week and discuss their practical Product Life Cycle (PLC) and
applications in product management and its implications for product
marketing strategy. management.

The final day of Week 2 focuses on final Reflecting on personal insights

Day –6 reflections and wrap-up activities and experiences gained during
Week 2.

9
 WEEKLY REPORT
4.4 WEEK – 2 (From From 15-01-24 To 21-01-24 )
Topic Covered: Product Life Cycle (PLC)

Description:

Week 2 delves into the intricate concept of the Product Life Cycle (PLC), which serves as a fundamental
framework for understanding the evolution of products in the marketplace. Participants explore the various
stagesthat a product typically progresses through during its lifetime, from introduction to decline, and gain
insights intothe strategies applicable at each stage to maximize profitability and market success.

The week begins with an overview of the Product Life Cycle (PLC), emphasizing its significance as a
dynamic model that traces the trajectory of a product's sales and profitability over time. Participants learn about
the distinct stages of the PLC, including introduction, growth, maturity, and decline, and examine the
characteristics and challenges associated with each phase. Through interactive lectures, case studies, and real-
world examples, participants gain a deeper understanding of the factors influencing the duration and dynamics
of each stage in the PLC. They explore the role of market demand, competitive forces, technological
advancements, and consumer preferences in shaping the trajectory of a product's life cycle. Moreover,
participants analyze the implications of the PLC for strategic decision-making and marketing planning. They
examine the different strategies and tactics employed by businesses to manage products at various stages of
the PLC, such as product differentiation, pricing adjustments, promotional campaigns, and extension
strategies.

Furthermore, participants explore the concept of product portfolio management within the context of the PLC,
considering how organizations strategically allocate resources and prioritize investments across a portfolio
of products with diverse life cycle stages. They discuss the importance of balancing investments in new
product development with efforts to sustain and optimize the performance of existing products.

In essence, Week 2 equips participants with a nuanced understanding of the Product Life Cycle (PLC) and
its implications for product management and marketing strategy. By comprehending the dynamics of product
evolution and the strategies applicable at each stage of the PLC, participants are better prepared to navigate
the complexities of the marketplace and drive sustained business growth and innovation

10
 4.5 ACTIVITY LOG FOR THE 3rd WEEK

PERSON IN
DAY BRIEF DESCRIPTION LEARNING
CHARGE
OUTCOME
OFTHE DAILY SIGNATURE
ACTIVITY

Begins with an introduction to the Understanding the critical role

Day –1 fundamental principles of mechanical of material selection in
design. mechanical design

Focuses on the critical aspect of Exploring the properties and

Day -2
Materials election in mechanical characteristics of various
design engineering materials.

Day –3 The principles of structural integrity Learning key concepts such as

andload analysis in mechanical design. stress, strain, deformation, and
failure modes.

Day –4 Dedicated to hands-on design Analyzing mechanical system

exercises where participants apply the sand identifying design flaws.
principles learned in real-world
scenarios.

Integrating knowledge of
Day –5 The concepts learned throughout the material selection, structural
week and reflecting on the importance integrity, and design principles
ofmechanical design fundamentals. inmechanical engineering.

Addressing any remaining

Day –6 Participants engage in final reflections questions or concerns
andwrap-up activities about mechanical
design fundamentals.

11
 WEEKLY REPORT
4.6 WEEK – 3 (From 22-01-24 To 28-01-24)

Topic Covered: Mechanical Design & Considerations - Part 1.

Description:

Week 3 marks the initiation into the realm of mechanical design, where participants delve into the fundamental
principles and considerations essential for designing robust and efficient mechanical systems. This session
primarily focuses on the foundational aspects of mechanical design, including material selection, structural
integrity, and design principles.

Participants are introduced to the critical role of material selection in mechanical design and its profound
impact on the performance, durability, and cost-effectiveness of engineered products. They explore various
types of engineering materials, such as metals, polymers, ceramics, and composites, and learn how to evaluate
their mechanical properties, including strength, stiffness, toughness, and corrosion resistance.

Moreover, participants delve into the principles of structural integrity and load analysis, understanding how
mechanical components and systems withstand external forces and stresses. They learn about keyconcepts such
as stress, strain, deformation, and failure modes, and explore analytical techniques for assessing the structural
integrity of mechanical designs. Throughout the session, participants engage in hands-on activities, case
studies, and design exercises to apply the principles learned in real-world scenarios. They analyze examples
of mechanical components and systems, identify design flaws and optimization opportunities, and propose
solutions to enhance performance and reliability.

By the end of Week 3, participants develop a solid foundation in mechanical design fundamentals, equipped
with the knowledge and skills necessary to embark on more advanced topics in mechanical engineering. They
gain a deeper appreciation for the intricate interplay between material selection, structural integrity, and design
optimization in the creation of innovative and resilient mechanical systems.

12
Fig.2. Mechanical Design Process

13
 4.7 ACTIVITY LOG FOR THE 4th WEEK

DAY BRIEF DESCRIPTION LEARNING PERSON IN

OUTCOME
OFTHE DAILY CHARGE
SIGNATURE
ACTIVITY

Begins with an exploration of tolerance Understanding the significance

Day –1 analysis, a critical aspect of mechanical of tolerance analysis in
design. mechanical design.

Advanced optimization techniques Exploring parametric

aimed at enhancing the efficiency, optimization and its applications
Day -2 reliability, and cost-effectiveness of in design refinement.
mechanical designs.

Participants engage in hands-on exercises Practicing tolerance stack-up

focused on tolerance analysis. analysis to predict assembly fit
Day –3 and functionality.

dedicated to practical applications of Using parametric optimization to

optimization techniques in mechanical refine design parameters.
Day –4 design.

focuses on integrating the concepts Integrating knowledge of

learned throughout the week and tolerance analysis and
Day –5 reflecting on their practical applications optimization techniques in
inmechanical design. mechanical design

Facilitators lead a review of the practical Addressing any remaining

applications of tolerance analysis and questions or concerns about
Day –6 optimization techniques covered during advanced mechanical design
the week. concepts.

14
 WEEKLY REPORT
4.8 WEEK – 4 ( From 29-01-24 To 4-02-24 )

Topic Covered: Mechanical Design & Considerations - Part 2

Description:

Week 4 elevates participants' understanding of mechanical design as they delve deeper into advanced
concepts and methodologies. Building upon the foundational principles introduced in the previous week,
this session focuses on refining design strategies and exploring sophisticated techniques to optimize
mechanical systems.

Participants begin by exploring tolerance analysis, a critical aspect of mechanical design that involves
assessing the variation in dimensions and tolerances of individual components within an assembly. They
learn how to perform tolerance stack-up analysis to predict the cumulative effects of dimensional variations
on assembly fit, functionality, and manufacturability. Through hands-on exercises and case studies,
participants gain proficiency in identifying tolerance issues, determining appropriate tolerances, and
implementing tolerance optimization strategies to improve product quality and performance.

Furthermore, participants delve into optimization techniques aimed at enhancing the efficiency, reliability,
and cost-effectiveness of mechanical designs. They explore methods such as parametric optimization,
topology optimization, and finite element analysis (FEA) to systematically improve design parameters
while considering constraints such as weight, material usage, and manufacturing constraints. Through
practical applications and simulations, participants gain insights into the iterative process of design
optimization, where they iteratively refine designs to achieve desired performance objectives.

By the conclusion of Week 4, participants emerge with a deeper appreciation for the intricacies of advanced
mechanical design concepts and their significance in creating robust and optimized mechanical systems.
They areequipped with practical skills and analytical tools to address complex design challenges and drive
innovation in mechanical engineering.

15
 4.9 ACTIVITY LOG FOR THE 5th WEEK

DAY BRIEF DESCRIPTION OF LEARNING OUTCOME PERSON IN

THE DAILY ACTIVITY CHARGE

SIGNATURE

Participants are introduced to the real- Beginning to develop project

time projects for Week 5, which simulate management skills by setting
practical design challenges encountered in project goals and timelines
Day –1 various industries.

participants focus on developing their Enhancing teamwork and

conceptual designs based on the ideas collaboration skills through
generated during the ideation phase group discussions and feedback
Day -2 sessions.

prototyping and testing the developed Conducting tests to assess the

designs. Participants use various performance and functionality of
Day –3 prototyping techniques to create physical prototypes
ordigital prototypes of their products.

Participants engage in iterative design Developing adaptability and

processes to refine their prototypes based resilience by navigating design
Day –4 on testing feedback and analysis. challenges and setbacks.

focuses on finalizing designs and Developing presentation skills to

preparing presentations to showcase effectively communicate project
Day –5 projectoutcomes. outcomes

The final day involves presentations of the Receiving and providing

completed projects and reflections on the constructive feedback on project
Day –6 overall learning experience presentations.

16
 WEEKLY REPORT
4.10 WEEK – 5 ( From 5-02-24 To 11-02-24)

Topic Covered: Real-Time Project.

Description:

Week 5 marks a pivotal transition from theoretical learning to practical application as participants engage
in real-time projects. This immersive experience offers an invaluable opportunity for students to bridge the
gap betweenclassroom instruction and real-world scenarios, fostering the development of essential skills
and competencies inproduct design and development.

In this week's session, on hands-on projects that simulate real-world design challenges encountered in
various industries. Guided by experienced mentors or instructors, we apply the theoretical knowledge
acquired in previousweeks to solve practical problems, design innovative solutions, and navigate the
complexities of productdevelopment processes.

The real-time projects encompass a diverse range of design tasks, spanning concept ideation, prototyping,
testing,and iteration. Participants collaborate in teams or work independently, depending on the project
scope, to brainstorm ideas, develop conceptual designs, create detailed drawings or models, and validate
their designs through testing and analysis.

Throughout the project duration, participants are encouraged to apply critical thinking, problem- solving
skills, and creativity to overcome obstacles and deliver viable solutions. They learn to navigate constraints
such as budgetary limitations, time constraints, and technical requirements while striving to meet project
objectives and stakeholder expectations.

By actively engaging in real-time projects, participants not only reinforce their understanding of theoretical
concepts but also cultivate essential competencies such as project management, teamwork, communication,
and adaptability. Moreover, the hands-on experience gained during this week empowers students to
transitionseamlessly from academic settings to professional environments, equipped with the practical skills
and confidenceneeded to excel in the field of product design and development.

17
 4.11 ACTIVITY LOG FOR THE 6th WEEK

DAY BRIEF DESCRIPTION LEARNING OUTCOME PERSON IN

OFTHE DAILY CHARGE
ACTIVITY SIGNATURE

Day-1 Participants are introduced to the Understand the importance of

fundamental principles of DFMA, DFMA in product development.
focusing on optimizing design to enhance
manufacturing efficiency
andeffectiveness
Day-2 This day explores strategies for Recognize the benefits of
minimizing part count and making parts simplifying product designs
multi-functional to simplify product through part count reduction
designs and reduce manufacturing
complexity.

Day-3 Participants delve into the principles of Understand the importance of

designing parts to be self-aligning and self-alignment and self-location
self-locating, which helps streamline in assembly processes.
assembly processes and improve product
quality.
Day-4 This day focuses on utilizing stack Learn strategies for optimizing
assemblies and ensuring the ease of the handling of parts from bulk.
handling parts from bulk to streamline
production workflows.

Day-5 Participants explore strategies for Recognize the importance of

eliminating interfaces and designing parts error-proofing in enhancing
that cannot be installed incorrectly to product reliability and assembly
reduce assembly errors and improve efficiency.
product reliability.
Day-6 The final day emphasizes the principles of Understand the benefits of
maximizing part symmetry and maximizing part symmetry and
encouraging modular assembly encouraging modular assembly

18
 WEEKLY REPORT
4.12 WEEK – 6 ( From 12-02-24 To 18-02-24 )

Topic Covered: DFMA - Part 1.

Description:

Week 6 delves into the fundamental principles of Design for Manufacturability and Assembly (DFMA), a
criticalaspect of product development aimed at optimizing design to enhance manufacturing efficiency and
effectiveness.

Participants will explore the foundational concepts of DFMA, including the integration of
manufacturability considerations into the design process to streamline production workflows, minimize
costs, and improve productquality. Through engaging lectures and practical examples, students will gain
insights into the importance of early-stage design optimization and the key principles guiding DFMA
implementation. The session will highlight strategies for simplifying product designs, reducing
manufacturing complexity, and minimizing the number of parts and assembly steps required for production.
Participants will learn how to identify and address design features that may hinder manufacturability, such
as tight tolerances, complex geometries, or material constraints.

Principles of DFMA are: -

• Minimize part count

• Make Parts Multi-Functional
• Design parts to be self-aligning and self-locating.
• Use stack assemblies.
• Ensure the ease of handling of parts from bulk.
• Eliminate Interfaces.
• Design parts that cannot be installed incorrectly.
• Maximize part symmetry if possible or make parts obviously asymmetrical.
• Use Standard Parts and Hardware.
• Simplify and Optimize the Manufacturing Process
• Encourage modular assembly

19
Moreover, the session will emphasize the significance of collaboration between design engineers and
manufacturing teams to ensure seamless integration of DFMA principles throughout the product
development lifecycle. By adopting a holistic approach to design optimization, participants will discover
how DFMA can driveinnovation, enhance product performance, and accelerate time-to- market while
minimizing manufacturing costsand risks.

Overall, sets the stage for participants to embrace the principles of DFMA as an integral part of their product
design toolkit, empowering them to create designs that are not only innovative and functional but also
practical and cost-effective to manufacturing.

Fig.3. Methodology of DFMA

20
 4.13 ACTIVITY LOG FOR THE 7th WEEK

PERSON IN
DAY BRIEF DESCRIPTION OF LEARNING CHARGE
THE DAILY ACTIVITY OUTCOME SIGNATUR
E
Day-1 Participants are introduced to advanced Understand the importance of
DFMA methodologies, focusing on advanced DFMA methodologies
optimizing manufacturing processes and in optimizing manufacturing
minimizing production costs processes.

Day-2 This day explores advanced DFMA tools Learn how to use DFMAsoftware
and software solutions designed to to identify potential design
streamline manufacturing workflows improvements and quantify cost
and enhance product quality. savings
opportunities.
Day-3 Participants explore best practices for Recognize the benefits of
integrating DFMA considerations into incorporating feedback from
the product development lifecycle, from manufacturing and supply chain
initial design concept to final production. stakeholders in design iterations.
They learn strategies for collaborating
effectively across cross-functional teams
Day-4 This day features case studies illustrating Analyze case studies to
the application of advanced DFMA understand the challenges and
techniques in real-world scenarios, opportunities associated with
including multi-component assemblies advanced DFMA methodologies.
and high-volume production
environments.
Day-5 Participants explore strategies for Learn strategies for iterating on
continuous improvement in DFMA, design iterations and optimizing
focusing on iterating on design iterations manufacturing processes over
and optimizing manufacturing processes time.
over time.
Day-6 he final day focuses on mastering Master advanced DFMA
advanced DFMA techniques, techniques for optimizining
empowering participants to drive manufacturing processes an
innovation, improve product reducing production costs.
performance, and achieve competitive
advantage

21
 WEEKLY REPORT
4.14 WEEK – 7 ( From 19-02-24 To 25-02-24 )

Topic Covered: DFMA - Part 2.

Description:

Week 7 builds upon the foundational principles introduced in Week 6 by delving into advanced Design for
Manufacturability and Assembly (DFMA) techniques aimed at optimizing manufacturing processes and
minimizing production costs.

Participants will explore advanced DFMA methodologies and tools designed to streamline manufacturing
workflows, enhance product quality, and reduce time-to-market. Through interactive sessions and case
studies, students will gain insights into the application of DFMA principles in complex design scenarios,
including multi-component assemblies and high-volume production environments.

The session will cover advanced DFMA tools and software solutions that enable engineers to analyze and
optimizeproduct designs for manufacturability and assembly efficiency. Participants will learn how to
leverage DFMA software to identify potential design improvements, simulate manufacturing processes,
and quantify cost savingsopportunities.

Moreover, the session will focus on best practices for integrating DFMA considerations into the
productdevelopment lifecycle, from initial design concept to final production. Participants will explore
strategies for collaborating effectively across cross-functional teams, incorporating feedback from
manufacturing and supply chain stakeholders, and iterating on design iterations to achieve optimal results.

By mastering advanced DFMA techniques, participants will be equipped with the knowledge and skills to
drive innovation, improve product performance, and achieve competitive advantage through optimized
manufacturingprocesses and cost-effective design solutions.

22
 4.15 ACTIVITY LOG FOR THE 8th WEEK

BRIEF DESCRIPTION OFTHE LEARNING PERSON IN

DAY DAILY ACTIVITY OUTCOME CHARGE
SIGNATURE

Day-1 Participants are introduced to casting as a Understand the importance of

fundamental method in manufacturing casting processes in
industries. They learn about the manufacturing
significance of casting in producing
complex shapes and intricate
components with high dimensional
accuracy.
Day-2 his day focuses on sand casting, one of Understand the basics of sand
the oldest and most versatile casting casting and its components
processes. Participants learn about the
sand-casting process, including pattern
preparation, mold cavity creation, metal
pouring, and finishing operations
Day-3 Participants explore advanced sand- Gain insights into advanced
casting techniques and applications. sand-casting techniques and
They delve into topics such as mold optimization strategies
design optimization, gating systems, and
alloy selection to improve casting quality
and efficiency.
Day-4 This day introduces investment casting, Learn about the steps involved in
also known as lost-wax casting. the investment casting process
Participants learn about the investment
casting process, including pattern
creation, mold assembly, shell building,
dewaxing, metal pouring, and finishing.
Day-5 Participants explore advanced Gain insights into advanced
investment casting techniques and investment casting techniques
applications. They examine topics such and optimization strategies
as rapid prototyping for pattern creation,
ceramic shell process optimization, and
post-casting treatments to enhance
component properties.
Day-6 The final day focuses on the integration Understand the factors to conside
of casting processes into product design when selecting casting processes
and manufacturing strategies. for product manufacturing.

23
 WEEKLY REPORT
4.16 WEEK – 8 ( From 26-02-24 To 03-03-24 )

Topic Covered: Introduction to Casting Process - Part 1

Description:

Week 8 provides an introduction to casting processes, a fundamental method in manufacturing industries.

Participants will delve into the basics of casting, including sand casting and investment casting, and explore
theirwide-ranging applications in product manufacturing.

The session will begin with an overview of casting as a manufacturing process, highlighting its significance
in producing complex shapes and intricate components with high dimensional accuracy. Participants will
learn aboutthe different types of casting methods, focusing primarily on sand casting and investment casting
techniques.

Sand casting, one of the oldest and most versatile casting processes, involves the use of sand molds to create
metal components. Participants will gain insights into the sand casting process, including pattern
preparation, mold cavity creation, metal pouring, and finishing operations. Through illustrations and
demonstrations, students will understand the advantages, limitations, and applications of sand casting in
various industries.

Investment casting, also known as lost-wax casting, offers precision and intricacy in manufacturing
components with complex geometries. Participants will explore the investment casting process, from
pattern creation and mold assembly toshell building, dewaxing, metal pouring, and finishing. Through case
studies and examples, students will analyzethe suitability of investment casting for producing high-quality,
dimensionally accurate parts in industries such asaerospace, automotive, and jewelry manufacturing. By the
end of the session, have a solid understanding of the principles and applications of casting processes, laying
the foundation for further exploration into advanced casting techniques and their integration into product
design and manufacturing strategies.

24
 Fig.4. Steps in Sand Casting

Fig.5. Steps in Investment Casting

25
 4.17 ACTIVITY LOG FOR THE 9th WEEK

DAY BRIEF DESCRIPTION LEARNING PERSON IN

OFTHE DAILY OUTCOME CHARGE
ACTIVITY SIGNATURE

Day-1 Participants are introduced to die casting as an Learn about the advantages
advanced casting technique for producing of die casting in mass
intricate, dimensionally accurate components production applications
with excellent surface finish.

Day-2 This day explores the applications of die Analyze case studies to
casting and presents case studies illustrating its understand the practical
use in various industries, such as automotive implications of die casting
and consumer electronics

Day-3 Participants are introduced to permanent mold Recognize the importance

casting, also known as gravity die casting, as of mold materials and gating
an advanced casting method offering systems in permanent mold
advantages in terms of dimensional accuracy casting
and surface finish.
Day-4 This day focuses on optimization techniques Gain insights into
for permanent mold casting to improve casting optimization techniques for
quality and productivity. Participants explore permanent mold casting
topics such as mold materials, gating systems,
and process parameters, with an emphasis on
optimizing casting quality and minimizing
defects.
Day-5 Participants delve into quality control Explore defect prevention
measures and defect prevention strategies in strategies and quality
advanced casting techniques. They explore assurance measures
methods for identifying and addressing
common casting defects such as porosity,
shrinkage, and surface imperfections.
Day-6 The final day focuses on process optimization Understand the principles o
and implementation in advanced casting process optimization in
techniques advanced casting techniques

26
 WEEKLY REPORT
4.18 WEEK – 9 ( From 4-03-24 To 10-03-24 )

Topic Covered: Introduction to Casting Process - Part 2

Description:

Week 9 delves deeper into casting processes, focusing on advanced techniques such as die casting and
permanent mold casting. Participants will explore these advanced casting methods, emphasizing process
optimization and quality control measures to enhance productivity and product quality.

Die casting is a high-speed, high-pressure casting process used to produce intricate, dimensionally accurate
components with excellent surface finish. Participants will learn about the die casting process, including
molddesign, metal injection, solidification, and ejection. Through case studies and practical examples,
students willunderstand the advantages of die casting in mass production applications, such as automotive
and consumer electronics industries.

Fig.6. Die Casting

Permanent mold casting, also known as gravity die casting, offers advantages in termsof dimensional
accuracy and surface finish compared to sand casting. Participants will examine the permanentmold casting
process, from mold preparation and metal pouring to solidification and part removal.

27
Throughout the session, emphasis will be placed on quality control measures and defect prevention
strategies in advanced casting techniques. Participants will explore methods for identifying and addressing
common casting defects such as porosity, shrinkage, and surface imperfections. By understandingthe
principles of process optimization and quality assurance, students will be equipped to implement efficient
and reliable casting processes in industrial applications

Fig.7. Permanent Mold Casting

28
 4.19 ACTIVITY LOG FOR THE 10th WEEK

PERSON IN
DAY BRIEF DESCRIPTION OF LEARNING CHARGE
THE DAILY ACTIVITY OUTCOME SIGNATURE

Day-1 Overview of forging processes: open-die Participants will grasp the

forging and closed-die forging. Basic fundamental concepts of
principles of metal deformation and shaping. forging and understand its
Importance of forging in industrial significance in modern
manufacturing. manufacturing
Day-2 Detailed explanation of open-die forging Participants will
process. Heating methods for metal comprehend the steps
preparation. Types of hammers and presses involved in open-die
used in open-die forging. Material selection forging and recognize its
and considerations for open-die forging. advantages in producing
large, custom-shaped
components
Day-3 In-depth exploration of closed-die forging Participants will gain
process. Die design considerations for closed- insight into the intricacies of
die forging. Preheating techniques for metal closed-die forging and its
billets. Sequence of operations in closed-die applications across different
forging. Factors influencing material flow and sectors
grain structure.
Day-4 Understanding material behavior during Participants will grasp how
forging processes. Effects of temperature and material properties are
strain rate on material properties. Grain influenced by forging
structure evolution during forging. Mechanical processes, aiding in product
properties enhancement through forging. design and performance
optimization
Day-5 Examination of forged components in Participants will understand
automotive industry. Aerospace applicationsof the real-world applications
forged parts. Role of forging in energy sector. of forging processes and
Case studies highlighting the importance of their impact on product
forging in product performance. performance, reliability,
and cost-effectiveness
Day-6 Overview of recent advancements in forging Participants will gain insight
technology. Emerging trends in die design and into the latest developments
manufacturing. Integration of automation and in forging technology and
digitalization in forging processes. anticipate future trend
Sustainability considerations in forging enabling them to stay
operations. competitive in the evolving
manufacturing landscape

29
 WEEKLY REPORT
4.20 WEEK – 10 ( From 11-03-24 To 17-03-24 )

Topic Covered: Forging Processes.

Description:

Week 10 focuses on forging processes and their applications in industrial manufacturing. Explore the
principles and techniques involved in forging, including both open-die forging and closed-die forging
methods.
Open-die forging, also known as free forging, involves deforming metal between flat dies or anvils to
achievethe desired shape. Participants will learn about the open-die forging process, from heating the metal
to forgingit into shape using hammers or presses. Through demonstrations and case studies, students will
understand the advantages of open-die forging in producing large, custom-shaped components with
improved mechanical properties.

Fig.8. Closed Die Casting

Closed-die forging, also referred to as impression forging, utilizes shaped dies to confine and shapethe metal
into the desired form. Participants will explore the closed-die forging process, including die design,
preheating of metal billets, and the forging sequence. Attention will be given to factors influencing material
flow, grain structure, and mechanical properties in closed-die forging operation. Additionally, the session
willcover the applications of forging processes in various industries, including automotive, aerospace, and
energysectors.

We will examine real-world examples of forged components and their role in enhancing product
performance, reliability, and cost- effectiveness. By the end of the week, will have a comprehensive
30
understanding of forging processes and their applications,empowering them to make informed decisions in
product design and manufacturing.

Fig.9. Open Die Forging

31
 4.21 ACTIVITY LOG FOR THE 11th WEEK

BRIEF DESCRIPTION OF THE LEARNING PERSON IN-

DAY DAILY ACTIVITY OUTCOME CHARGE
SIGNATURE

Hands-on experience in developing Understanding the

educational content. importance of thorough
Day 1 planning and research in
course development.

Experience in giving and receiving Enhanced skills in content

constructive feedback for improvement. creation, particularly in
Day 2 addressing soft skills
development.

Ability to incorporate feedback and make Experience in giving and

revisions to improve course content. receiving constructive
Day 3 feedback for improvement.

Experience in pilot testing and gathering Ability to incorporate

insights for course refinement. feedback and make
Day 4 revisions to improve course
content.

Experience in project management and Experience in pilot testing

meeting deadlines. and gathering insights for
Day 5 course refinement.

Experience in pilot testing and gathering Ability to incorporate

insights for course refinement. feedback and make
Day 6 revisions to improve course
content.

32
 WEEKLY REPORT
4.22 WEEK –11 ( From 18-03-24 To 24-03-24 )
Topic Covered: Introduction of Forging.

Description:

Week 11 delves deeper into the world of forging, focusing on advanced techniques and applications in
industrial manufacturing. Participants will explore the principles, processes, and applications of forging,
witha particular emphasis on both cold forging and hot forging methods.

Cold forging, also known as cold forming, involves deforming metal at room temperature or slightly above
toproduce components with high dimensional accuracy and surface finish. Participants will learn about the
coldforging process, including material selection, lubrication techniques, and tool design considerations.
Throughcase studies and practical demonstrations, students will gain insights into the advantages of cold
forging in producing complex-shaped components with minimal material waste.

Hot forging, on the other hand, involves deforming metal at elevated temperatures to enhance formability
and reduce forging forces. Participants will explore the hot forging process, including heating methods, die
design, and temperature control measures. Attention will be given to the metallurgical changes that occur
during hot forging, leading to improved mechanical properties and grain structure in forged components.
Furthermore, the session will cover the applications of cold and hot forging techniques across diverse
industries,including automotive, aerospace, and construction sectors. Participants will analyze real-world
examples of forged components and their role in optimizing product performance, durability, and cost-
efficiency. By the end of the week, participants will have gained comprehensive insights into advanced
forging techniques and their applications, equipping them with the knowledge to leverage forging processes
effectively in product design and manufacturing.

Types of Forging:

1. Open Die Forging: Also known as smith forging, it involves placing a piece of metal between flat dies
and then deforming it using hammer blows or presses. The metal is not fully confined, allowing it to flow
outward, resulting in a product with rough surfaces and non-uniform grain structure.

2. Closed Die Forging: Also called impression die forging, it involves placing a piece of metal within a
die set containing one or more cavities.

33
3. Roll Forging: This process involves shaping metal by passing it between two cylindrical rollers. The
rollers exert compressive forces on the metal, causing it to deform and take the shape of the die cavities.
Roll forging is often used to produce long, cylindrical parts like shafts and axles.

4. Swaging: Swaging is a forging process that involves reducing the diameter or thickness of a metal rod
or tube by forcing it through a die or series of dies. It is commonly used to produce components with tapered
or profiled shapes, such as pins, needles, and gun barrels.

5. Upset Forging: Also known as heading or heading and upsetting, this process involves increasing the
cross-sectional area of a metal work piece by applying compressive forces to one end. Upset forging is
commonly used to form heads on bolts, rivets, and other fasteners, as well as to create larger diameter
sections in shafts and bars

Fig.10. Cold Forging

34
 4.23 ACTIVITY LOG FOR THE 12th WEEK

BRIEF DESCRIPTIONOF LEARNING PERSON IN-

DAY THE DAILY ACTIVITY OUTCOME CHARGE
SIGNATURE
Initial planning and brainstorming Understanding the
session. Defined course objectives and importance of thorough
Day 1 target audience. planning and research in
course development.

Research phase: Identified key topics Ability to define clear

and industry trends to be covered in objectives and target
Day 2 the course. audience for educational
content.

Research phase: Identified key topics Ability to define clear

and industry trends to be covered in objectives and target
Day 3 the course. audience for educational
content.

Drafted outline and curriculum Understanding the

structure for the course. importance of thorough
Day 4 planning and research in
course development.

Developed course materials for the Hands-on experience in

first module, focusing on technical developing educational
Day 5 disciplines. content.

Created interactive learning activities Understanding of

and assessments for the module. different instructional
Day 6 methodologies and their
application in course
design.

35
 WEEKLY REPORT
4.24 WEEK – 12 ( From 25-03-24 To 31-03-24 )
Topic Covered: Sheet Metal Process

Description:

Week 12 focuses on the fundamental principles and techniques involved in sheet metal fabrication, a critical
aspect of modern manufacturing processes. Participants will explore various aspects of sheet metal
processing,including cutting, bending, forming, and joining techniques, along with their applications across
diverse industries.

The session begins with an overview of the properties and characteristics of sheet metal materials commonly
used in fabrication, such as steel, aluminum, and stainless steel. Participants will learn about material
selectionconsiderations based on factors such as strength, ductility, and corrosion resistance, ensuring
optimal performance and durability of fabricated components. Next, the session delves into cutting
techniques used insheet metal fabrication, including shearing, punching, laser cutting, and water jet cutting
methods. Participantswill gain insights into the advantages and limitations of each cutting method, along
with factors influencing process selection, such as material thickness, geometry complexity, and production
volume.

Subsequently, the focus shifts to bending and forming operations, essential processes for shaping sheet
metalinto desired geometries. Participants will learn about bending principles, tooling requirements, and
techniquesfor achieving precise bend angles and tolerances. Additionally, the session covers various
forming methods, including stamping, deep drawing, and roll forming, along with considerations for
material flow, spring back,and forming defects.

The session also addresses joining techniques used in sheet metal fabrication, such as welding, riveting,
and adhesive bonding, emphasizing factors like joint strength, corrosion resistance, and assembly
efficiency. Through case studies and practical demonstrations, participants will gain insights into the
selection of appropriate joining methods based on application requirements and material compatibility.

By the end of the week, participants will have a comprehensive understanding of sheet metal fabrication
processes and their applications across industries, enabling them to design and manufacture sheet metal
components efficiently and cost-effectively.

36
Fig.11. Sheet Metal Process

37
 4.25 ACTIVITY LOG FOR 13th WEEK

BRIEF DESCRIPTIONOF LEARNING PERSON IN-

DAY THE DAILY ACTIVITY OUTCOME CHARGE
SIGNATURE
Continued development of course Enhanced skills in content
materials for the second module, creation, particularly in
Day 1 emphasizing soft skills. addressing soft skills
development.

Conducted peer review and Experience in giving and

feedback session for Module 1 receiving constructive
Day 2 materials. feedback for
improvement.

Finalized course materials for Ability to incorporate

Module 2 and integrated feedback feedback and make
Day 3 from peer review. revisions to improve
course content.

Prepared promotional materials and Understanding of the

marketing strategy for the importance of marketing
Day 4 upcoming course launch. and promotion inattracting
learners.

Conducted pilot testing of the Experience in pilot testing

course with a small group of and gathering insights for
Day 5 learners. course refinement.

Analyzed feedback from pilot Adaptability in making

testing and made necessary quick adjustments based
Day 6 adjustments to course materials. on user feedback.

38
 WEEKLY REPORT
4.26 WEEK – 13 ( From 1-04-24 To 07-04-24 )

Topic Covered: Casting Components - 3D Modeling.

Description:

In Week 13, will delve into the realm of 3D modeling specifically tailored for casting components, a crucial
aspect of modern product design and development processes. This session focuses on leveraging advanced
software tools such as SolidWorks or AutoCAD to create detailed digital models of components intended
forcasting processes.

The session begins with an overview of casting processes and their unique requirements for component
design. Participants will gain insights into the characteristics of casting materials, such as metal alloys or
polymers, and understand how these properties influence the design process. Emphasis will be placed on
considerations such as draft angles, fillets, and parting lines to facilitate the casting process and minimize
defects.

Next, participants will be introduced to the principles and techniques of 3D modeling, utilizing industry-
standard software platforms. Through interactive demonstrations and hands-on exercises, participants will
learn how to create accurate and detailed digital representations of casting components, incorporating
geometric features, surface finishes, and dimensional tolerances.

The session will cover essential modeling tools and commands for creating complex geometries commonly
encountered in casting applications, such as intricate part geometries, undercuts, and internal features.
Participants will also explore techniques for optimizing designs for manufacturability, ensuring that the
digitalmodels are compatible with casting processes and capable of producing high-quality components.

Throughout the session, participants will engage in practical exercises and case studies to reinforce their
understanding of 3D modeling concepts and their application to casting component design. By the end of
the week, participants will have acquired the skills and knowledge necessary to create robust and
manufacturing3D models of casting components, laying the foundation for effective product design and
development in thecasting industry.

39
 4.27 ACTIVITY LOG FOR THE 14th WEEK

BRIEF DESCRIPTION LEARNING PERSON IN-

DAY OF THE DAILY OUTCOME CHARGE
ACTIVITY SIGNATURE

Finalized course materials and Experience in project

prepared for the official launch. management and meeting
Day 1 deadlines.

Launched the course on Skill Dzire Understanding of the

platform and initiated enrolment. importance of a successful
Day 2 launch and ongoing
support for course
participants.

Continued research and started Refine outline and begin

drafting outline and curriculum development of course
Day 3 structure for the course. materials for the first
module.

Refined outline and began Continue development of

development of course materials course materials and start
Day 4 for the first module. planning interactive
learning activities.

Continued development of course Complete development of

materials for the first module. course materials and
Day 5 Started planning interactive finalize interactive
learning activities. learning activities for
Modules.

Complete development of course Begin development of

materials and finalize interactive assessments for Modules
Day 6 learning activities for Modules. and prepare for peer
review.

40
 WEEKLY REPORT
4.28 WEEK – 14 ( From 8-04-24 To 14-04-24 )

Topic Covered: Sheet Metal Components - 3D Modeling.

Description:

In Week 14, participants will embark on an exploration of advanced 3D modeling techniquestailored for
sheet metal components, an integral aspect of modern product design and manufacturing processes. This
session delves into the intricacies of creating detailed digital models of sheet metal parts using industry-
standard software tools like SolidWorks or Autodesk Inventor.

The session commences with an overview of sheet metal fabrication processes and their uniquerequirements
for component design. Participants will gain insights into the characteristics of sheet metal materials,
such as thickness, bend allowances, and material properties, andunderstand how these factors
influence the design process. Emphasis will be placed on incorporating design features such as bends,
flanges, and reliefs to achieve the desired form and function of sheet metal components.

Next, participants will be introduced to advanced 3D modeling techniques specific to sheet metal design.
Through interactive demonstrations and hands-on exercises, participants will learn how to leverage
specialized modeling tools and commands to create complex geometriescommonly encountered in sheet
metal applications. Topics covered include creating parametric models of sheet metal parts, defining bend
profiles, and incorporating features suchas stiffening ribs and lances.

Throughout the session, participants will explore strategies for optimizing sheet metal designs for
manufacturability and assembly, ensuring that the digital models are compatible with fabrication
processes and capable of meeting performance requirements.

By the end of the week, participants will have acquired the skills and knowledge necessary toproficiently
create robust and manufacturing 3D models of sheet metal components, empowering them to tackle
complex design challenges and drive innovation in the field of product design and manufacturing.

41
Fig.12. Sheet Metal Components

42
 4.29 ACTIVITY LOG FOR THE 15th WEEK

BRIEF DESCRIPTIONOF LEARNING PERSON IN-

DAY THE DAILY ACTIVITY OUTCOME CHARGE
SIGNATURE
Developed assessments for Conduct peer review
Modules and prepared for peer session and gather
Day 1 review. feedback for
improvements.

Conducted peer review session for Incorporate feedback and

Modules materials and gathered make revisions to
Day 2 feedback. Modules materials.

Continued development of course Conduct peer review

materials for the second module, session for Modules
Day 3 emphasizing soft skills. materials.

Conducted peer review session for Make revisions to

Modules materials and gathered Modules materials based
Day 4 feedback. on feedback and prepare
for pilot testing.

Made revisions to Modules Conduct pilot testing of

materials based on feedback and the course with a small
Day 5 prepared for pilot testing. group of learners.

Conducted pilot testing of the Analyze feedback from

course with a small group of pilot testing and make
Day 6 learners. necessary adjustments to
course materials.

43
 WEEKLY REPORT
4.30 WEEK – 15 ( From 15-04-24 To 21-04-24 )

Topic Covered: Plastic Components - 3D Modeling.

Description:

Week 15 focuses on the intricate process of designing plastic components using advanced 3D modeling
techniques. Plastic components play a crucial role in various industries, from consumer electronics to
automotive manufacturing, and mastering their design is essential for product innovation and development.

During this week, participants will gain a comprehensive understanding of the unique considerations
involved in designing plastic components. One of the key aspects explored is theutilization of 3D modeling
software, which enables designers to create intricate and precise digital representations of plastic parts.
Through hands-on exercises and tutorials, students will learn how to navigate these software tools
effectively, mastering features such as parametric modeling, surface modeling, and assembly design.

Fig.13. Plastic Components - 3D Modeling.

44
 CHAPTER 5: CONCLUSION

The conclusion for a product design should summarize the key points of the design process, highlight the
main features and benefits of the product, and reinforce its value proposition. It should also emphasize how
the design addresses user needs and solves their problems effectively. Additionally, the conclusion can
touch upon any future improvements or iterations that could enhance the product further. Here's an example
of a conclusion for a product design:

"In conclusion, our product design represents a culmination of extensive research, innovative thinking, and
user-centric design principles. By carefully considering user feedback and market trends, we have
developed a product that not only meets but exceeds customer expectations. With its sleek design, intuitive
interface, and advanced features, our product offers unparalleled convenience and functionality to users.
Furthermore, its focus on sustainability and durability aligns with modern consumer preferences for eco-
friendly products. Moving forward, we remain committed to continuous improvement and innovation,
ensuring that our product evolves to meet the ever-changing needs of our customers. We are confident that
our design will make a significant impact in the market and enhance the lives of our users."

From personal to professional use, our product offers a seamless experience tailored to meet the demands
of diverse users. Whether it's simplifying everyday tasks for individuals or streamlining complex workflows
for businesses, our design provides unparalleled convenience and efficiency. With its sleek design, intuitive
interface, and advanced features, our product finds applications in numerous industries, including
healthcare, education, entertainment, and beyond. In healthcare, it can facilitate remote patient monitoring
and improve communication between healthcare professionals. In education, it can enhance learning
experiences through interactive presentations and collaborative tools. In entertainment, it can provide
immersive experiences for gamers and multimedia enthusiasts.

45