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Mr. George Molakal
Board Member - STAMOD
A graduate of Harvard Business School and Oxford
University Mr. Molakal has successfully handled over 30+
cross border Mergers & Acquisitions transactions across US,
India, MENSEA, and China and built several companies
globally. As the CEO of ALCOR Fund, Mr. Molakal aims to
drive value to customers globally through its range of
portfolio companies
Mr. Mike Katz
Board Member – STAMOD Engineering
Mr. Katz is a graduate of Harvard Business School.
He has a successful track record of turning
companies into highly profitable units. He is
responsible for building growth and leadership in
corporations. He has worked with GE and Cummins
in various senior positionsacrossthe world
Management team
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Mr. Eric Cohen
Board Member - STAMOD Engineering
A graduate from Harvard Business School, and
Eng. Graduate of Univ. of Wisconsin. He has been
the Managing Partner of W HI PEG whilst acquiring
21 companies. Served as the CEO of Ampere and
has established multiple JV’s in Asia, Heads the
Global Ops of PPS and has been the India and
China Lead trader for GE.Has managed several
funds in the US.
Dr. JagannathVedula
Board Member – STAMOD Engineering
Jagannath Vedula has Doctorate in Management Information
Systems (MIS) and Masters in Computer Applications with
an extensive experience in the field of computers, managing
outsourced projects with their associated security issues &
risks. Dr. Vedula has managed numerous projects in various
fields in his 23 years of Experience and has successfully
completed them in the given timelines and budget. As the
Director of Stamod, he is responsible for the growth,
operations, client retention and management of Stamod. “
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Types of Services
• Onsite (Commissioning, Startup or Engineering - as part of customer’s engineering team)
• Remote Engineering Centre (REC) Services (Design, Development and Testing services)
• Hybrid Engineering Services (Integrated Onsite & Offsite services)
• Standardization Projects
Flexible Costin
Flexible Partnership Business Model
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• Time & Material
• Fixed Cost Type
• Cost Advantage for Remote Engineering Centre (REC) agreement engagements
Size of Projects
• Few Man weeks projects
• Multi Man-Year projects
• Complete project cycle including project management and customer coordination
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• Dedicated & Independent Line for
File transfer (FTP) and Web tools
• Independent & Dedicated set up
for Video conf ./
• 10,000 square feet facility
• 3-shift operation for meetingdeliver due dates
Infrastructure and Tools
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Data Confidentiality
Protecting IPR
o Non Confidentiality Agreement with employees
o NDA with vendors and contractors
o Need to know philosophy
o Secure data transfer practices
o Secure networks & facilities through an extensive
firewall & secure FTP setup
Information Security
o Experienced certified team involved in design &
implementation of information security
o Trace ability and audit logs
o Anti virus protection for all desktops and mail
services and internet gateways
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Physical Security
o Proximity card based access to premises
o Second level access control and authentication for accessing server rooms
and shared resources
o 24x7 Security, stringent policies on device/media handling
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Subsystem design Testing & Validation Crash
CFD NVH Industrial design
Tolerance Stack up VE/VA
L3Proto Typing
In-house Capability
Partnered Capability
NPD competence
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Modeling Drawing Legacy Data conversion FE Meshing Technical illustration (EIP)
Reverse Engineering Concept creation Advance 3D Modeling
Standardization Design automation Part / Component designs
Manufacturing Drawing creation Detailed Design
L1
L2 CAE & FE Analysis Injection Mold Design
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Automotive Industry
CFD Capabilities in:
◦ Internal and External Aerodynamics
◦ Intake/exhaust manifolds
◦ Underhood Analysis
◦ Filtration and Exhaust Systems
◦ HVAC/Defrosting Ducting
External Aerodynamics Engine Simulation
Filtration SystemUnderhood thermal managementHVAC Ducting
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1. Structural Validation.
•Functional Load Analysis (Linear, Non Linear )
•Abuse Load Analysis (Linear , Non Linear )
•Buckling Analysis , Top Loading / Bust Analysis
•Weight Optimization
2 . Vibration Analysis /JIS D 1601
CAE/ FE Analysis – Strategic Alliance
Software : Pre Processer
Hypermesh I Ansa
,
MIL-STD-202G )
•Frequency Response (JIS D1601 )
•High Cycle Fatigue Analysis
3.Thermal Analysis
• Steady State Thermal Analysis
• Transient Thermal Analysis
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4. Crash Analysis
1. Air Bag Validation: Linear impactor
2. Interior Fitting Crash : FMVSS 201, ECE R 21
3. Seating Analysis : ECE R 14/ ECE R 15 / ECE R
16 / ECE R 17
4. Bumper Analysis : AIS 006 / EURO NCAP
5. RUPD/ FUPD/ SUPD / Rollover
CAE/ FE Analysis – Strategic Alliance
5. Impact Analysis
1. Drop Test
2. Helmet Impact Test ECE R 22.05 / BIS
6. CFD Analysis
1. Air Vent , Air Intel , Condensation
Software : Solver expertise :
Optistruct I LS DYNA I Radioss I Pam Crash I Abaqus IPost Processing
Hyperview
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Moldflow SimulationMoldflow Simulation
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Visor : Flow Analysis
Filling Problems :
1. Flow not balanced
2. Critical air trap formation
3. High filling pressure
• Objective
o Identify Tool cracking issues & rectify them
Methodology of Project Execution
o Detailed flow analysis with existing molding
conditions & identified the filling problems
o Rectified the causes by analysis iterations
• Deliverables/ Outputs delivered
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, ,
cavity pressure, Clamp tonnage, Weld line
o Molding process inputs along with flow leader
details
• Benefit to Customer o More tool life (Earlier tool & mainly pressure pads
were cracking)
o Identified molding process methodology for the
part & material which can be used for repetitive
molds as it is higher production volume.
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Thickness increased from 2.1 to 2.3
Thickness increased from 2.1 to 2.4
Visior Part Changes:
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Conclusion:
1. Good correlation observed between molded part & Moldflow simulation
2. Cause for tool crack is due to higher cavity pressure
3. Flow leader helped to improve flow balance & reduce pressure
4. Pressure reduced by 17 % (120 MPa Vs 100 MPa)
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Product Desi nProduct Desi n
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Product Design – Interiors & Exteriors
o Inputs : Class A Surface
o Deliverables : B surface creation , Engineering
details & Closed volume part
o Quality Check : Draft analysis in molding axis
• Parametric Modeling - B pillar
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o Inputs: Class A Surface ( Optics Surface )
o Deliverables : Optics surfaces as per draft criteria and
Offset thickness and integration with main Housing
o Quality Check : Draft analysis in molding axis, Surface quality,
thickness check, fillets etc.
• Tail Lamp - Housing Design
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Re-designed Console
Processed Point
cloud data
Surface from
point cloud data
Front Console
Digital Image of
physical sample
Re - Engineering
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Final fitment position
in the vehicle
Prototype
o Reverse engineer existing console
o Develop bracket for mounting console and cup holder
o Develop RPT of console, bezel and bracket
o Fitment trials, modifications and design freeze
Console
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Tool Desi nTool Desi n
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Consumer/ White Goods• Project Details
o Model Features: Door - Intermediate
o Domain: Plastic: Styron 498
o Duration/Work hours: 50 hours
• Objective
o Injection Molding
o Design delivery in time with no errors.
• Deliverables
COMPONENT
MOVING HALF ASSEMBLY
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o 3D CAD models
o 2D drawings
• Benefit to Customer
o Designs are delivered in account of good machining
feasibility.
o Kinematics are considered in design stage to avoid
failures in trials or actual.
o All areas of design of mold are planned with inserts.
(Grill areas and weak steels)
FIXED HALF ASSEMBLY
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Gate LocationsFirst injection point
Second injection point
Medical
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4-Drop Hot runner in 2 places for separate injection.
Needs to discuss for bench mark for filling or mold flow analysis
64-Cavity Balm Top Cover
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Mold opening sequences
Second opening for part
removal
Mold process sequence
1. Mold close
2. First Injection (Red
part)
3. Mold cooling
4. First opening for
runner layout drop-
out.
5. Second opening core
and cavity6. Stripper plate rotation
°
64-Cavity Balm Top Cover
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First opening for runner
and sub-runner removal
Opening distance 95.0mm
7. Mold close
8. Injection in both
Nozzles for RED and
WHITE part.
9. Mold cooling
10. First opening for
runner layout drop-
out.11. Second opening core
and cavity
12. Part Ejection
13. Stripper plate rotation
to 180°
14. Next cycle start
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Stripper rotation 180° for second part injectionMovement of stripper 40.0mm
64-Cavity Balm Top Cover
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First option is
Stripper plate
rotation with
INDEXING PLATE
for Second partInjectionOPTION 1: INDEXINGPLATE SYSTEM
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Second option is Moving half rotation with ROTARY TABLE for
Second part Injection
OPTION 2: ROTARY
TABLE
64-Cavity Balm Top Cover
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Mold Design
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Moving Half Assembly
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Mold Design
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Fixed Half Assembly
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Automotive
Spoiler FrontPart Name :- Spoiler Front
Material :- PP
Shrinkage :- 1.1%
No. of Cavities :- Single
Type of Mold :- Standard Injection Mold
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MOLD TOP
R S
I D E
O L D I N G
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O P E R A T O
D -
S L I DE - 3
Mould Layout-1
D-MOLDING
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Mold Design
Fixed Half Assembly
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Next Steps
• ND Agreement
• Analysis of Scope (Onsite/Remote/Offshore)
• Pilot (Free Trial Project upto 50 hrs.)
• Project work
NDA & Pilot
• STAMOD and Customer to review progress every
month and look for areas to improve efficiency and
process
Business
Review
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Thank You
U.S. Office-1: Chicago - 8770 W Bryn Mawr Ave, Suite 1300, Chicago, IL 60631
Tel : +1 800 507 4489Fax No. +1 877 284 0818
U. S. Office 2: Austin - 7613 Baja CV, Austin; TX 78759
India Office : Commerzone, Bldg.no.2. Office no.305, Yerawada. Pune 411 006
Tel: +91 20 66870000
Fax: +91 20 66870087
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