Project

Developing a Door Trim Panels

GGirish Reddy14 Apr 2023

Objective: Creating a Door trim panel from given class A surface by using Catia V5 .

Given below is the procedure to create a new plastic component from given class A surface .

Creation of tooling axis
Creation of class b surface
Creation of class C surface
Creation of closed body
Draft Analysis

The Main Components in the given Surface is:

1) Arm rest

2) Map pocket (Consists of upper and lower part)

3) Upper substrate (Not given in the current model)

4) Lower substrate .

Class A surfaces of all parts:

Refers to those surfaces which are visible in a product either interior or exterior. This service is primarily used in the automotive environment and increasingly in consumer goods. It is a requirement where aesthetics have a significant contribution.

Arm Rest:

Lower Substrate:

Upper Map Pocket:

Lower Map Pocket:

Creation of Tooling axis:

Arm Rest:

Lower Substrate:

Upper Map Pocket:

Lower Map Pocket:

Creation of class B surface:

Procedure to create class B surface for Lower substrate .

Step 1: Use offset tool with a distance value of 2.5mm to create offset of class A surface .

Step 2: After offsetting , extrapolate tool was used to extend all the edges of this surface . This is done to ensure that the parting line comes at B surface .

Step 3: In areas where extrapolate was not possible (Fillet or cusped surfaces) multisection surface option was used .

Arm Rest:

Lower Substrate:

Upper Map Pocket:

Lower Map Pocket:

3) Creation of Class C surface

Procedure for creation of class C surface for Upper map pocket

Step 1: Use sweep command to create a new surface an an angle with respect to a surface . This angle is dependant on draft angle for free edges and ususally 90 degree for mating surfaces .

Arm Rest:

Lower Substrate:

Upper Map Pocket:

Lower Map Pocket:

Hence class C was created for all components .

Creation of Closed Body:

Arm Rest:

Lower Substrate:

Upper Map Pocket:

Lower Map Pocket:

Push Pin Clip:

Heat Stakes:

Dog House:

Step 1: Create a point on required location and a plane from it . Create a sketch with base sketch for dog house .

Step 2: Use sweep tool to create a surface using this profile and draft direction at a draft angle of 1.5 degrees.

Step 3: Use extrapolate and extrude option to create required surfaces and use trim and split to obtain the outer body of dog house .

Step 4: Create a new body and name it as dog house 1 . Use thick surface option to create a solid of required thickness .

Step 5: To create ribs, create and sketch and use pad tool to create a solid and union trim it with dog house .

Creation of Ribs:

Step 1: Create a sketch and create a surface . Use thick surface option to obtain ribs in required shape .

Step 2:Use Translate option to place ribs wherever required.

Use Boolean operation union trim to trim it with lower substrate main body .
Create heat stakes and flanges at required locations using above mentioned procedures to obtain complete substrate body . Apply draft on all required surfaces and fillets on all straight edges.

Dog House, Ribs & Heat Stakes:

Draft analysis :

1)Once the tooling axis is created , publish it and the component using Publication from tool option .

2)Insert Feature draft analysis option from insert tool bar

3) Change the view option to customize view parameters and click on material option under shading .

4) Now click on the axis option from Draft analysis tools , allign it with tooling axis and click on lock option to lock it .

5) Change draft angle value to 3 degree . Click on quick analysis mode to display feature according to given color scale . Check from all views to ensure the draft analysis is cleared .

6) Since the created tooling axis does not clear the draft analysis at the created axis , click on the lock axis button to unlock it . Now rotate the tooling axis by left clicking on the top round portion of the axis system . Rotate the axis till maximum clearance is obtained . Now right click on the axis and click lock current axis .

7) Create a line using the initial axis origin and this axis using point and direction (using compass direction) option . This is our required tooling axis .

8) Now if we check for draft analysis, we can observe that the ribbed area has not yet cleared draft analyisis. Hence we need to create a side core tooling axis . To do this , create a line using point and direction option with Y direction .

9) Repeat steps 1 to 5 to ensure the remaing portion which was not cleared using Tooling axis has been cleared using this axis .

Arm Rest of Class A & Final Body: