Development of a Door Trim panel
OBJECTIVES:
Creation of CAD model considering following inputs as like in OEM and tier1 companies
- a) Class A surface
- b) Nominal thickness : Refer master sections
- c) Attachment strategy :
Find a attachment strategy for the door panel complete work.
Use Push pin with Dog house for Lower substrate – Door panel attachment
Use heat stakes for part to part attachment
Output required:
- Create thickened part using master section for reference
- Create the mounting features as per design guidelines in the industry and with master sections
- Apply material details :
- Draft analysis & Tooling analysis
- Creation of parting lines and check tooling feasibility
Output required in attachment
- Submit the CATpart and CATproduct in the attachment
Introduction :
The ten stages in automotive product life cycle developement are listed below .
1)Concept sketch
2) Styling class A
3)Feasilbility check
4)Concept validation
5)New product design
6)Product developement
7) Prototyping
8)Design validation
9)Pilot production
10)Mass production
From the above stages , it isin stage 5 that new product is developed and validated from class A surface . The objective is to design class B and class C surface from given class A surface and create a solid body from it using softwares like CATIA V5, solidworks or solidedge taking into consideration the draft analysis which makes the component suitable for production using injection molding process .
procedure to create a new plastic component from given class A surface .
1) Creation of tooling axis
2) Creation of class b surface
3) Creation of class C surface
4) Creation of closed body
5) Draft Analysis .
Draft analysis is done to ensure that the designed part is manufacturable based on the draft conditions applied. It is done to ensure the proper ejection of the component from dies(for metals) or molds(for plastics). The basic idea is to ensure that the tooling axis has to be created in such a wat that it has no parallel surface profiles of the component so that the ejection of the components can be ensured . Tooling axis is the axis along which cavity and core are closed and opened .
The main components of interior door panel of a car consists of the following parts .
1) Arm rest
2) Map pocket (Consists of upper and lower part)
3) Upper substrate (Not given in the current model)
4) Lower substrate .
PROCEDURE OF DOOR TRIM PANEL :
1) Arm Rest :-
Step 1: Design Check on received Class A :-
- After receiving the Class-A for the connectivity of the surfaces on it.
- Use boundary operation and disassemble.
- Check for discontinuous Surface.
- The check is over if any discontinuities do not arise.
Step 2: Determine the tooling Axis :-
- Identify faces which can potentially create problems while manufacturing.
- Surfaces at angles along a desired Tooling Axis.
- Extract a plain surface and create a point on its center for Axis system creation.
Step 3: Draft Analysis on Class-A and Possible Creation of Side Tooling Axis :-
- Change View Mode Customization to Material mode.
- Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
- Change the range to 3°. Apply the settings as shown in below image.
- The input Class A also has walls having negative angle to the tooling axis.
- This can be an issue while manufacturing the component as it would be very difficult to draw from the molds.
- So, this design needs to consider Various Side Tooling Options.
- Here also we can see that some faces are not clearing draft analysis and it is due to the improper class A surface and we have to imform our styling team to modify the class A surface.
Step 4: Class-B Surface Creation :-
This can be done by offseting the class-A surface and by reparing the patches that are forrmed while offsetting the class-A surface.
- First offset the class-A surface
- We can observe it has created patches at two stages.
- So we have to repair them by using multi section surface command.
- Name the developed repaired surface ass Class-B Surface and make it publish.
Step 5: Class-C Surface Creation :-
- Extract Class A boundary and convert to Smooth Curve.
- Sweep the curve to the Class A.
- Sweep value should be greater than the Thickness required for part.
- The obtained sweep is shown in Figure.
- Join the Class A Surface with the Class C surface to create a single surface entity.
Step 6: Enclosed Surface Creation :-
- Trim the obtained surface with Class B surface.
- Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
- The final Enclosed Surface Obtained is shown in Figure.
- Closed Surface :- Make the final trim to solid part using close surface.
Step 7: Perform Draft Analysis on Final Enclosed Surface:
- Change View Mode Customization to Material mode.
- Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
- Change the range to 3°. Apply the settings as shown if Figure.
Views of Door Arm Panel :
B) Lower Substrate :-
Step 1: Design Check (Pre Check) on received Class A :-
- After receiving the Class-A for the connectivity of the surfaces on it.
- Use boundary operation and disassemble.
- Check for discontinuous Surface.
- The check is over if any discontinuities do not arise.
Step 2: Determine the tooling Axis :-
- Identify faces which can potentially create problems while manufacturing.
- Surfaces at angles along a desired Tooling Axis.
- Extract a plain surface and create a point on its center.
- Create the intersection by using the plane.
- Create the bisecting line for tooling axis by taking dummy tooling axis.
Step 3: Draft Analysis on Class-A :-
- Change View Mode Customization to Material mode.
- Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
- Change the range to 3°. Apply the settings as shown in below image.
Step 4: Class-B Surface Creation :-
- The creation of class-B surface can be done by smiply offsetting the class-A surface to the required distance and required direction.
Step 5: Class-C Surface Creation :-
- Extract Class A boundary and convert to Smooth Curve.
- Sweep the curve to the Class A.
- Sweep value should be greater than the Thickness required for part.
- The obtained sweep is shown in Figure.
- Join the Class A Surface with the Class C surface to create a single surface entity.
Step 6: Enclosed Surface Creation :-
- Trim the obtained surface with Class B surface.
- Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
- The final Enclosed Surface Obtained is shown in Figure.
Closed Surface :-
Make the final trim to solid part using close surface.
Step 7: Perform Draft Analysis on Final Enclosed Surface:
- Change View Mode Customization to Material mode.
- Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
- Change the range to 3°. Apply the settings as shown if Figure.
Views of Lower Substrate :
C) Outer Map Pocket :-
Step 1: Design Check (Pre Check) on received Class A :-
- After receiving the Class-A for the connectivity of the surfaces on it.
- Use boundary operation and disassemble.
- Check for discontinuous Surface.
- The check is over if any discontinuities do not arise.
Step 2: Determine the tooling Axis :-
- Identify faces which can potentially create problems while manufacturing.
- Surfaces at angles along a desired Tooling Axis.
- Extract a plain surface and create a point on its center for Axis system creation.
Step 3: Draft Analysis on Class-A :-
- Change View Mode Customization to Material mode.
- Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
- Change the range to 3°. Apply the settings as shown in below image.
Step 4: Class-B Surface Creation :-
- The creation of class-B surface can be done by smiply offsetting the class-A surface to the required distance and required direction.
Step 5: Class-C Surface Creation :-
- Extract Class A boundary and convert to Smooth Curve.
- Sweep the curve to the Class A.
- Sweep value should be greater than the Thickness required for part.
- The obtained sweep is shown in Figure.
- Join the Class A Surface with the Class C surface to create a single surface entity.
Step 6: Enclosed Surface Creation :-
- Trim the obtained surface with Class B surface.
- Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
- The final Enclosed Surface Obtained is shown in Figure.
- Closed Surface :- Make the final trim to solid part using close surface.
Step 7: Perform Draft Analysis on Final Enclosed Surface:
- Change View Mode Customization to Material mode.
- Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
- Change the range to 3°. Apply the settings as shown if Figure.
Views of Outer Map Pocket :
D) Inner Map Panel :
Step 1: Design Check (Pre Check) on received Class A :-
- After receiving the Class-A for the connectivity of the surfaces on it.
- Use boundary operation and disassemble.
- Check for discontinuous Surface.
- The check is over if any discontinuities do not arise.
Step 2: Determine the tooling Axis :-
- Identify faces which can potentially create problems while manufacturing.
- Surfaces at angles along a desired Tooling Axis.
- Extract a plain surface and create a point on its center.
- Create the intersection by using the plane.
- Create the bisecting line for tooling axis by taking dummy tooling axis.
Step 3: Draft Analysis on Class-A :-
- Change View Mode Customization to Material mode.
- Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
- Change the range to 3°. Apply the settings as shown in below image.
Step 4: Class-B Surface Creation :-
- The creation of class-B surface can be done by smiply offsetting the class-A surface to the required distance and required direction.
Step 5: Class-C Surface Creation :-
- Extract Class A boundary and convert to Smooth Curve.
- Sweep the curve to the Class A.
- Sweep value should be greater than the Thickness required for part.
- The obtained sweep is shown in Figure.
- Join the Class A Surface with the Class C surface to create a single surface entity.
Step 6: Enclosed Surface Creation :-
- Trim the obtained surface with Class B surface.
- Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
- The final Enclosed Surface Obtained is shown in Figure.
Closed Surface :-
Make the final trim to solid part using close surface.
Step 7: Perform Draft Analysis on Final Enclosed Surface:
- Change View Mode Customization to Material mode.
- Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
- Change the range to 3°. Apply the settings as shown if Figure.
Views of Inner Map Pocket :
5) DESIGN OF B-SIDE FEATURES :
- First Create Flanges where ever required on the part bodies. The purpose of flange is to accomodate heatstakes on the part bodies.
- After creating the flanges create heat stakes at the places where flanges are present. For the thickness and diameter of the heat stakes refer to the master section which is given in the challenge.
- Then create a clearance hole on the flanges which we have created previously. The clearance between flange and heat stake must be 0.1mm.
- After creating the heat srakes create ribs on the lower substrate. The main purpose of creating ribs is to support the flange as well as ribs under the application of large pressure and force when the process of melting heat stakes is happening.
- Then after attach the push pin to the dog house by using proper assembly constraints.
PUSS PIN
DOG HOUSE
FLANG
HEAT STAKES
6) Views of the final assembly of Door Trim Panel :
- Front View
- Back View
- Left View
- Right View
- Top View
- Bottom View
- Isometric View
8) Tree Structure :
