Production Steps of

Building Static Mockup of

the CAR
A Report
Submitted in Partial Fulfillment of the
Requirements for the Degree
B.Sc.Project in Production Engineering
Department of Mechanical Engineering, Faculty of Engineering,
Helwan University

By
Aly Ahmed Faragallah Hesham Mohamed
Othman
Moustafa Fathi Moustafa Mohamed
Mohamed Ibrahim
Moustafa Mohamed Mosaab Hossam Abdin
Zakey
Mohamed M. Hassan Mahmoud
Soliman M.MohamedElsayed

Under supervision

Prof. Morcos Ibrahim Ghobrial

Prof. Nader Farahat Hassan
1
 Dr. Hussein M.A Hussein

Helwan-Egypt
2016
Acknowledgement
Apart from the efforts of our teammates, the success
of the project depends largely on the encouragement and
guidelines of many others. We take this opportunity to
express our gratitude to the people whom helps have been
instrumental in the successful completion of this
project. We would like to show our greatest appreciation
to Prof. Morcos Ibrahim Ghobrial, Prof. Nader Hassan
Farahat, Dr. Hussein Mohamed Abdel-Moneim.
We cannot say thank you enough for his tremendous support
and supervision. We feel motivated and encouraged every
time during the project in progress. Without his
encouragement and guidance this project would not have
materialized and finished within our expectation.
On the other hand, we would like to express our gratitude
towards to Mr. Mostafa Hassan a designer at 3D scale CO.
from Lebanon for helping us in the model that being
manufactured by using 3D printing. Our thanks and
appreciations also go to Aamen Bahnassi for helping us in
manufacturing the laser model and finishing the 3D model at
the workshop in the faculty of applied arts Helwan
university .

2
Contents: -
Page
Chapt Introduction 1
er 1
1. Preface 1
1
1. Objectives for 1
2 students
1. Objectives for the mechanical department 2
3
1. Objectives for the 2
4 country
1. The project 2
5 implementation
steps
Chapt Product 4
er 2 concept
2. The idea broaching sources 4
1
2. Sketching 5
2
2.2 2D sketching 5
.1
2.2 Selecting the winning sketches 6
.2
2.2 Converting the winning sketches into 2D 7
.3
Chapt Using CAD for building the surface 8
er 3 models
3. advantages of CAD systems: 8
1

3
 3. The basic geometrical approaches available to 8
2 designers on CAD systems
3. The most popular free form curves: 8
3
3. The tools used for building the surface models. 9
4
3. How to build surface model of Audi TT body by 10
5 using SOLIDWORKS as a CAD software:
Chapt The applying of hard points on the 16
er 4 models
4. Automotive Ergonomics 16
1
4. Hard points 17
2
4.2 Main groups of hard points 18
.1
4.2 The list of hard points 19
.2
4.2 Vision test 27
.3
4.2 Solid works Customization 28
.4
4.2 Customized vision test 30
.5
3. GCIE 32
2
Chapt Manufacturing
er 5
5. The mockup building methods
1
5. The selected methods for building the models
2
5.2 Hand made
.1
5.2 Laser cutting
.2
5.2 3D printing
.3
5.2 Machining
.4
Chapt Testing and result
er 6

4
Chapt Automotive design terminology
er 7
Appendices
Referenc
es

List of figures: -
Figure Title Page
Figure 2.1 group with their 2D and 3D sketches 6
Figure 2.2 group with their 2D and 3D sketches 6
Figure 2.3 group with their 2D and 3D sketches 6
Figure 2.4 group with their 2D and 3D sketches 6
Figure 3.1 collecting the blue prints 7
Figure 3.2 starting drawing the door 8
Figure 3.3 drawing the side skirt 8
Figure 3.4 drawing the bonnet 8
Figure 3.5 drawing the hood 8
Figure 3.6 cutting extends 8
Figure 3.7 drawing the upper part of the door 8
Figure 3.8 forming the side skirt to suit the design 8
Figure 3.9 drawing the window frame of the door 8
Figure drawing the roof 9
3.10
Figure positioning the wheel home 9
3.11
Figure cutting the extends to get the car opening 9
3.12
Figure drawing the rocker panel 9
3.13
Figure forming the rocker panel to suit the design 9
3.14
Figure forming the fender 9
3.15
Figure forming the tail gate 9
3.16
Figure forming the doors 9

5
3.17
Figure filling the gaps 10
3.18
Figure drawing the back lighting area 10
3.19
Figure forming the back bumper to suit the design 10
3.20
Figure cutting the extends 10
3.21
Figure filling the gaps 10
3.22
Figure drawing the back bumper 10
3.23
Figure forming the number panel area 10
3.24
Figure completing the surface 10
3.25
Figure drawing the area of exhaust tip 11
3.26
Figure the front grille 11
3.27
Figure cutting the extends 11
3.28
Figure drawing the exhaust tip 11
3.29
Figure the front bumper 11
3.30
Figure forming the accessories of the front lighting 11
3.31
Figure forming the car lock 11
3.32
Figure forming the mirror 11
3.33
Figure adjusting the position of the mirror 12
3.34
Figure link the mirror to the body 12
3.35

6
Figure the front lighting 12
3.36
Figure changing the material and coloring the body 12
3.37
Figure checking for defects 12
3.38
Figure the front view of the car body 12
3.39
Figure the back view of the car body 12
3.40
Figure 4.1 SAE recommended occupant packaging 14
Figure The Forward vision possibility of the driver 25
4.2.
Figure The camera interface inside Solid Works 26
4.3.
Figure The Camera side menu 26
4.4.
Figure The vision test at a distance of 6 meters 27
4.5.
Figure The vision test at a distance of 8 meters 27
4.6.
Figure The vision test with inclined angle to the left 28
4.7.
Figure The vision test with inclined angle to the right 28
4.8.
Figure The vision test for the dashboard (inside the car 29
4.9. itself)