Development of a Door Trim panel

Report :

Development of a Door Trim panel

AIM: Creation of CAD model considering following inputs as like in OEM and tier1 companies

1. a) Class A surface
2. b) Nominal thickness: Refer to master sections
3. c) Attachment strategy :

Use Pushpin with Dog house for Lower substrate – Door panel attachment

Use heat stakes for a part to the part attachment.

The project deals with the explanation of steps and procedures followed while developing the Door Trim Panel of a car using CATIA V5. Using the given class A surface tooling axis, class B surface, class C surface were created, and after forming the solid body from that the flanges and the B side features such as Dog house, push pins, Heat stakes, etc were built. And finally, the draft analysis is also done on the components to check the manufacturability of the components.

INTRODUCTION:

Front Door Panel

Door panels serve as an interface between the interior of the car and the inner workings of the door, and between vehicle occupants and the door. They are expected to meet a variety of design specifications regarding safety, aesthetics, and functionality. In addition, they are expected to continue the material theme of the dashboard and pillars while concealing intricate electrical and mechanical components for operating locks, windows, and other features.

In this project, an inner car door panel is given with class A surface, to create the door trim panel it is divided into sub-parts namely, a lower substrate, inner map pocket, outer map pocket, and door armrest.

GIVEN PART:

Sub Division:

Dividing the given surface into 4 parts to prepare each part individually for manufacturing and then assembling. The parts are created according to the master section given along with input.

1. LOWER SUBSTRATE:

Class A and Tooling axis:

Multiple extracted the subparts of the surface for lower substrate and using join command created a single class A surface. Some parts were not properly aligned so by joining command and sub-elements to remove that part and using multi-section surface to create a class A surface with no defects.

• Create a point on the class A surface to move the main tool for component creation on the base surface.
• Mask an axis over the point created with the same directions as the main axis.
• Using Intersect command from Generative Shape design select the YZ plane as the first element and the class A surface as the second element.
• After creating the intersecting lines select the Line command and join the vertices which show the most possible draft angle manufacturable.
• Bisect those two lines over the axis point we created

Draft analysis:

• After Tooling Axis Select the Feature Draft Analysis option from the Insert Option.
• Select the element to analyze.
• Next click on Use the compass to define the new current draft direction option and make it align with the tooling axis by dragging it to the axis.
• If the color appears blue just click the invert option on the right side of the draft direction axis button

Class B:

Using the Offset command and taking reference from the master section provided an offset of 2.5mm is given for the thickness of the part. Since fillets were creating problems for surface creation so by using the multi-section surface command the remaining surfaces were created.

Class C:

Here all the outer boundaries are extracted according to the requirements. Using sweep command with the draft direction of 3 degrees we get the CLASS C surface. The sweep was created in patches as connectivity error was occurring each sweep was extrapolated and trimmed together to create one single class C surface.

Final trim:

Finally, all surfaces were trimmed together as shown below.

2. OUTER MAP POCKET:

Class A and tooling Axis:

Draft analysis of class A

Class B:

Class C:

Final trim:

Draft analysis:

3. INNER MAP POCKET:

Class A and tooling axis:

Draft analysis:

Class B:

Class C:

Final trim:

Draft analysis:

4. DOOR ARMREST:

Class A

Draft analysis:

Class B

Class C

Final trim:

Draft analysis:

MOUNTING FEATURES AS PER DESIGN GUIDELINES:

FLANGES:

A flange is a protruded ridge, lip, or rim, either external or internal, that serves to increase strength (as the flange of an iron beam such as an I-Beam or a T-beam); for easy attachment/transfer of contact force with another object.

Below is the Sketch for the two flanges I selected for plastic parts joining.

According to the design rule and master, the section provided the flange thickness should be equivalent to the plastic component for rigidity and strength.

A minimum draft of 0.5 degrees and fillets of a minimum of 1 mm is given as per the master section.

DOG HOUSE:

Final Door trim Assembly:

CONCLUSION:

The door trim panel was successfully created with all the design rules taken into considerations for feature attachment and the main part was created using the master section provided with the input

class A.