Product Design and Prototype

  1. New concept generation (Conceptualization)

    We generate a concept that has a well-defined form including both a written and visual description, which includes its primary features and customer benefits combined with a broad understanding of the technology needed.

    What we do?
    • Generation, development and maturation of the opportunity into new ideas.
    • Translating the opportunity into specific ideas.
    • Adapting to an evolutionary process where ideas are built upon, torn down, combined, reshaped, modified and upgraded.
    • Categorizing ideas as formal (i.e. brainstorming, etc.) or informal (i.e. unusual request from customer, etc.)
    • Accommodate Most Effective Processes.

  2. Re-engineering for emerging markets

    In the post industrial age competition has intensified so much that If the organization cannot keep pace with the contemporary product design, it may fall short of having a significant share in the market. The consequence of the above situation necessitates reinventing ourselves; the methodology being Product Process Re-engineering.

    Our product re-engineering services range from slight renovation to a total overhaul by identifying and abandoning old and obsolete rules and assumptions that underlie the current practices; like improving the product's functionality, usability, stability and performance; change or adjust the architecture for another platform. This being discrete and a one-time event, is treated as a project which is critical to the organization and undergoes all the phases of development such as analysis, design and implementation.

  3. Cost Reduction Projects

    Many products can have a good control over their production overheads like utilities, raw materials, manufacturing processes, etc.; but little or no control on costs that are interwoven with the manufacturing operations and go unnoticed and sink the bottom line.

    We here at IIC adopt a special program dedicated to radical cost cutting in the manufacturing of the product without impairing the quality or productivity; by incorporating elimination of items / processes which increase the cost significantly.

  4. Reverse engineering

    Reverse engineering is a well-developed engineering practice for duplicating an item functionally and dimensionally where there is no existing CAD model. These processes include physical examination, measurements by various techniques, application of knowledge and experience to arrive at physical dimensions, attainable tolerances and material characteristics of an item for production / procurement. Also reverse engineering is viewed as a proven time-compression methodology for the development of any product variance.

    IIC-MCOE Reverse Engineering services are based on our experience, accumulated knowledge base and techniques. We have experience in every step of the reverse engineering process having handled many projects.
    • Use of various measurement techniques include CMM, Laser scanning etc. to map the surface data of any part, regardless of surface complexity using facilities in and around IIC.
    • Creation of cloud data to generate 3-D curves for constructing a parametric solid model using different techniques and software environments.
    • IIC-MCOE provides reverse engineering solutions to our clients with our knowledge and experience in the engineering design philosophies and processes like Design recovery, Forward engineering, Re-engineering, Tolerance development etc.

  5. Competitive evaluation

    IIC-MCOE's Competitive Evaluations deliver objective information on the products and competitors across a set of consistent measures that are defined by the current market of the product; i.e. the information that cannot be gathered from internal assessments or loosely structured competitive analysis programs.

    MCOE evaluates competitive brands in the industry and provides the client with an independent perspective and report on how the product is stacked up against local and national competition by having an insight into the strengths and weaknesses of the competitors' offerings and delivering a comprehensive snapshot of the competitive landscape.

    We typically examine each competitor's product or service offering, across the following categories of evaluation:
    • Competitive positioning / Market Share Analysis.
    • Business and pricing model utilized.
    • Comparative Technology Evaluation.
    • Products feature Comparison.
    • Market segmentation.
    • Marketing strategy evaluation.
    • Strength and Weakness Analysis.

  6. Detail design

    IIC-MCOE offers Detail Design Services to support engineering requirements that include:
    • Concept development.
    • Assembly, sub- assembly and part design; bill of materials and documentation.
    • Parametric Model Development.
    • Reverse Engineering
    • GD & T.
    • Detail Drawings.
    • Checking / Verification / Validation.
    • Release / PDM.

  7. Prototype

    The process of taking an idea and turning it into a tangible product; usually called the process of reducing the invention to practice has prototyping as its first step.

    Through prototyping:
    • An idea is brought to life and hence evaluating a product is apparent.
    • A developed prototype helps to work out the details of the product.
    • Identifying design flaws and weaknesses is made much easier when the product prototype is tested.

    This ensures that the product works the way it is intended to.

Analysis: FEA and CFD

Request for Case Studies

  1. Structural Analysis

    The domain of structural analyses deals with effects of external and internal loads on structures. These sets of analyses are critical in the design verification process, wherein the designs of critical structural components are affirmed to be safe for usage in industrial applications.

    1. Stress, Strain and Displacement Analysis:

      In this type of analyses, the stresses, strains and displacements caused by loads for corresponding boundary conditions are found. It is important to keep the stresses below the yield point of the material especially when the component is supposed to be operated within the linear elastic limit. Otherwise nonlinear analyses are conducted. It is also important to understand the deformation, since even though the stresses are within limit, the deformation may not be within the design limits. Accordingly a factor of safety is estimated from the determined loads. These estimates are then used in the design verification process to get approval from Certifying bodies, or for manufacturing purposes.

    2. Vibration Analysis:

      In this type of analyses, the effects of different types of varying loads (Cyclic, periodic, sinusoidal, etc.) are found, to keep the components isolated from the natural frequency of the system. In the event that the excitation frequency matches with the natural frequency of the system, dynamic amplification of the various modes of vibrations happen, causing failure of components due to high cycle or low cycle fatigue. Moreover, vibration analyses are also done in the interest of keeping vibrations within the comfortable noise levels. Also vibration analyses are done on products operated by humans to keep the vibrations below the natural frequency of the human body, for safety purposes.

    3. Design Calculations:

      In this type of work the concept design is verified for applicable loads and boundary conditions. Components are broken down into simple systems, like beams, plates, pressure vessels, and the free body diagrams are plotted. Further shear, bending and combined loads are estimated to find out the factor of safety of individual parts, assemblies and entire structures. Design calculations particularly help in supporting FEA studies and vice versa. Design Calculations are hence a useful tool for design validation.

    4. Fatigue Life Estimation and Durability Analysis:

      In this type of analyses, the life of parts and cumulative damage occurred to parts are estimated for varying load conditions. Under this case there are two broad types of analyses mainly low cycle and high cycle fatigue. High cycle fatigues are characterized by low strains and can be generally above 1000 cycles, whereas low cycle fatigues are characterized by high strains and less than 1000 cycles. Calculation of life and durability is critical in estimating warranty. Endurance studies like these are of particular importance in mobile applications like Aerospace, Automotive and industrial applications.

    5. Thermally induced stresses and Strains:

      In this type of analyses the stresses, strains and deformations that are induced due to thermal loads are estimated. If the stresses due to thermal strains have no provision to be relieved then, they will add up to the structural stresses and reduce the strength of parts to failure. Moreover, mechanical properties of parts deteriorate with thermal load thereby reducing the strength further. Hence it is important to estimate thermal stresses, especially for parts that are subjected to high operating temperatures, like furnaces, IC engine parts, components with high friction – brakes, clutches, etc.

  2. Flow Performance Analysis:

  3. In this domain the performance of fluid devices like, couplers, valves, pipe systems, etc. can be analyzed to estimate the flow coefficients, heat transfer capacity, pressure drops, velocity profiles etc., in the flow domain.

    1. Fluid flow studies:

      In this type of analyses, the flow coefficients, velocity and pressure profiles are studied. In the initial phase of concept design, CFD analyses can be used to extract the characteristic curves. Then the required changes can be made accordingly to the flow path, as per end customer expectations to suit requirement. This is especially suitable when physical testing is impossible in the absence of a functional prototype. Hence CFD analyses can be used as a methodology to construct robust, efficient designs.

    2. Heat transfer Analysis:

      In this type of analyses, the heat carrying capacity of fluids can be estimated for a particular flow speed, type of fluid, etc. In cases of thin film lubrication, viscous shearing causes temperature rise that adds to overall heat generation. Also with temperature rise, viscosity of the fluid gets reduced. The dynamic thermal effect here can be successfully studied by proper transient thermal analyses. With heat transfer analysis, we can estimate the temperature that can be expected to be seen at surfaces. With this, we can use suitable combination of materials to suit the final temperatures expected at the respective surfaces.

  4. Combined Analysis:

  5. Events happening in Mechanical systems are not just single physical phenomenon, but a combination of physics that are coupled. If we are able to identify the major physics in systems, then we can study them with the help of simulation tools by proper combination of the applicable physical equations.

    1. Coupled Thermal:

      Structural Analysis: In this type of analyses, structural strength of parts is studied under combined structural and thermal loads. Structural loads can be forces and torques and thermal loads can be heat power or temperature

    2. Coupled Flow-Thermal Analysis (CHT – Conjugate heat transfer analysis):

      In this type of analyses, flow performance is studied w.r.t heat carrying capability of a certain fluid flowing at certain velocity. As flow speed increases the heat carrying capability increases, hence it can be estimated as to what velocity (mass flow rate) of fluid is required to keep temperatures from increasing.

    3. Coupled Fluid-Structural Analysis (FSI):

      In this type of analyses the effect of structural and fluid dynamics on a system is studies. The fluid flow will cause pressurization of channel. The pressure causes geometry to change which again cause variation in pressure. This goes on till a static or dynamic equilibrium is achieved in the structure and the fluid. FSI studies are particularly important when the flow effect is considerable, to affect the structure (Ship and boat hulls, turbines, and flow through flexible walls) or the structural effect in considerable to affect the fluid (fluid bearing, pumps, etc.). The physical phenomenon can become more complicated with thermodynamic effects.

Sustaining Engineering

  1. Data conversion and 3D model development

    We have vast experience in data conversion; our proven methodologies are specifically designed to provide dependable conversions to our clients.

    Our focus is on parameters of time, productivity, quality and costs. Data quality and consistency are our watchword. We develop and use client specific reusable models to increase productivity and reliability; thereby helping our clients entrust the conversion / migration assignments to IIC-MCOE.

    With our engineering talent, we display proven methods of conversion under secure data environments. IIC-MCOE has perfected the conversion / migration processes to deliver quality form paper through 3D model. We offer complete range of conversions form one form to another with various available inputs like legacy documents, 2D drawings, 3D models and other client specific options delivering output in various standard digital formats as required by the client such as Pro-E models, Solidworks models, and CATIA models, IGES, STEP, and DXF/DWG.

    We emphasize on continuous improvements in conversion methods and processes so as to provide the highest quality and timely deliverables.

  2. Engineering Change Note (ECN) Support

    In our present complex product development and customization environment, where there is constant change due to technological advances, changing consumer demand, design issues or availability of specific components, some products or models of a particular batch would have to undergo ECN process. IIC-MCOE provides ECN services for various products of our OP-CO's containing the following information.
    • Identification of what needs to be changed; which includes the part number and name of the component and reference to the drawings that shows the component in detail or assembly.
    • Reason(s) for the change.
    • Description of the change; which includes a drawing of the component before and after the change. Generally, these drawings are only of the detail affected by the change.
    • List of documents and departments affected by the change. The most important part of making a change is to see that all pertinent groups are notified and all documents updated.
    • Approval of the change.
    • Instruction about when to introduce the change—immediately (scrapping current inventory), during the next production run, or at some other milestone.

  3. Production drawing and BOM

    We offer production drawing services that include 2D drafting of mechanical parts as well as assemblies from preliminary design data. These are accurately scaled & proportioned to ensure optimum accuracy in the mechanical component production drawings delivered.
    Our services include:
    • Mechanical equipment layouts & product installation drawings.
    • Mechanical schematics, sections & detailing.
    • Casting, machining, welding & assembly simulation drawings.

    We also offer services for Creation of Drawings and BOM (Bill of Materials). This includes bill of materials for assemblies that ultimately make it easy for clients to plan inventory levels as well as production.

  4. Fatigue Life Estimation

    We evaluate the fatigue life of the parts under various combinations of conditions like pulse fatigue and endurance fatigue; drawn on the basis of HCF / LCF (limited) theories of life cycle estimation.

    This helps understand criticalities of the design with respect to its durability, fatigue and fracture tolerances, including the causes of failure, recommended design changes for improvement and more.

Value Added Services.

CAM and Translations

IIC-MCOE provides industry specific Computer Aided Manufacturing services that include developing 3D surface /Solid Models from 2D drawing views and generating postprocessor CNC programs to be directly transferred to CNC controller. CNC programs for components involving 2, 3, 5 and 7-axis simultaneous milling and turning are undertaken.

Our Translation services include:

  • Translation of technical documents from its native language to the major languages of the world
  • Creation of glossaries/terminology databases