Development of a Door Trim panel

INTRODUCTION:

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 componets.

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.

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.they are:

1) arm rest.

2)lower substrate.

3)map pocket.

4)bottle holder.

ARM REST:

In the front of the car, a central armrest, which commonly folds away based on user preference, will also often include a storage compartment and sometimes even cup holders.

CLASS A SURACE:

CLASS A refers to those surfaces which are VISIBLE and abide to the physical meaning, in a product. This classification is primarily used in the automotive and increasingly in consumer goods (toothbrushes, PalmPC's, mobile phones, washing machines etc.).

Class A surfacing
is done using computer-aided industrial design applications. Class A surface modelers are also called
"digital sculptors" in the industry. Industrial designers develop their design styling through the ASurface, the physical surface the end user can feel, touch, see etc.

Class A is Visible surface and aesthetic look and surface with textures and it is Surfaces provided by customer.

DRAFT ANALYSIS OF CLASS A SURFACE:

The draft analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.

This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.The maximal draft analysis accuracy is 0.29 deg. According to the graphic card performance, this accuracy can be debased.

CLASS B SURFACE:

Class B surface:
1.invisible Surfaces.This Surface mostly don't have textures.Surface need to be create according to class-A surface. Having all features(Rib,boss,snap etc) in B-side surface only and Surfaces which is having TANGENT CONTINUITY IS CALLED class-B.

DRAFT ANALYSIS OF CLASS B SURFACE:

CLASS C SURFACE:

Class C surfaces are the backside surfaces that can have tool marks, flash and other imperfections without hurting appearance, function, etc.

Class C surface is normally created using the sweep command.Normally the C surface is nothing but adding thickness or filling the gap between the A surface and B
surface.

DRAST ANALYSIS ON THE CLASS C SURFACE:

• This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.
  These values are expressed in the unit as specified in tools >option > general > parameters > unit tab.
  You can modify them by clicking on their corresponding arrow or by entering a value directly in the field.
• The draft anlysis is done with the 0.29 draft angle.

CLASS ABC SURFACE:

ARM REST CLOSED SURFACE:

close surface means the part body with the all engineering features like flanges etc...

DRAFT ANALYSIS ON THE PART BODYOF ARM REST:

MULTI SECTION VIEW:

with this the all surfaces of the arm rest in different views is completed.

2)LOWER SUBSTRATE:

CLASS-A surface extraction:

Initially, we need to extract the CLASS-A surface for the Lower Substrate from the given input.

Draft Analysis on CLASS-A surface:

To ensure if the Tooling Axis we created is proper, we need to inspect the CLASS-A surface by performing a Draft Analysis on it.

CLASS-B surface:

To create the CLASS-B surface, the CLASS-A surface is offset by 2.5mm (since the thickness of the component is 2.5mm). From the master sections which is given to us as input, we can measure the thickness of the component.

At times few surfaces of the CLASS-B surfaces cannot be offset due to the change in the fillet region. These issues can be fixed by creating the surface manually in those portions. Since there are no issues on this surface we can proceed to the next step.

DRAFTING ANALYSIS OF CLASS B SURFACE:

The draft analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.

and the drafting angle is 2.9 degrees.

CLASS-C surface:

To create a CLASS C surface first extract the boundaries of the CLASS A surface.

After extracting the boundary, we need to perform a smooth (max. Deviation as 0.001mm) operation on it to create a continuous tangent surface.

DRAFT ANALYSIS ON THE CLASS C SURFACE:

using the ‘sweep’ option create the C surface by sweeping the boundary of the CLASS-A surface at an angle of 2.9deg outwards to the tooling direction.

The sweep option need to be performed seperately.it is not possible to create the c surface by a single boundary.

CLASS ABC SURFACE:

it is nothing but the closed surface.it is the combination of class a,class b,and class c surface.

DRAFT ANLYSIS OF CLASS ABC SURFACE:

drafting analysis is performed on the class abc surface with the reference of the tooling axes and the draft angle is2.9 degrees.

CLOSED SURFACE OF THE LOWER SUBSTRATE:

To form a closed surface we first need to join the CLASS A surface with the CLASS C surface and then trim this joined surface with the CLASS B surface to get the final output.If there will be any gaps after the joining of surfaces then these gaps need to be fixed to form a closed body.

Using the closed surface option in part workbench, a solid body from the closed surface can be formed.part body includes the all engineering additional features also.

DRAFT ANLYSIS ON THE PART BODY:

drafting analysis is performed on the class abc surface with the reference of the tooling axes and the draft angle is2.9 degrees.

This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.

MULTISECTION VIEW:

3)MAP POCKET:

MAP POCKET is the another part in the door trim panel.and this part is attaached to the lower substrate.it has also different surfaces.

CLASS A SURFACE:

This is the styling surface which provides the aesthetic features of a component. A designer starts the component design from a class A surface.It is also called the input part given by the customer and it is imported into the design platform.

DARFT ANALYSIS OF THE CLASS A SURFACE:

draft analysis was performed on the class a surface and the draft angle is 2.9 degrees.It is performed eith ethe reference of the the tooling axes.

CLASS B SURFACE:

class b surface is created by the offset the class a surface with the certain thickness.this surface isinvisible Surfaces.This Surface mostly don't have textures.Surface need to be create according to class-A surface. Having all features(Rib,boss,snap etc) in B-side surface only and Surfaces which is having TANGENT CONTINUITY IS CALLED class-B.

DRAFT ANLYSIS ON THE CLASS B SURFACE:

draft angle is 2.9 degrees and teken the reference of the tooling axes.

CLASS C SURFACE:

Class C surface is created along the tooling direction of the component and connects the class A and class B surfaces.

DRAFTING ANALYSIS ON THE CLASS C SURFACE:

Draft analysis measures the draft angle on multiple surfaces of a part along the tooling axis to check if the surfaces have the minimum required draft angle for it to be moulded properly.draft angle is 2.9 degrees.

CLASS ABC SURFACE:

it is the surface of the closed surface without the additional engineering features.iit is joining of class abc surfaces with out any gaps between the surfaces.

DRAFT ANALYSIS OF THE CLASS ABC SURFACE:

CLOSED SURFACE OF THE MAP POCKET:

closed surface means combining the all features and the surfaces without any gaps. it is also called the part body.it is attached the additional engineering features.and it is the final product.

DRAFT ANALYSIS OF THE PART BODY:

Draft analysis measures the draft angle on multiple surfaces of a part along the tooling axis to check if the surfaces have the minimum required draft angle for it to be moulded properly.draft angle is 2.9 degrees.including the engineering features drafting analysis is performed.

MULTISECTION VIEW:

BOTTLE HOLDER:

Bottle holder is one of the trim parts in the door. itnis used to hold the bottle or any cylindrical parts,it is attached to the lower substrate.it has the different surfaces like the all the surfaces.

CLASS A SURFACE:

Image below shows the Class A surface of the bottle holder. Tooling axis is created along Y direction.This is the styling surface which provides the aesthetic features of a component. A designer starts the component design from a class A surface.

DRAFT ANALYSIS OF THE CLASS A SURFACE:

Before proceeding to solid body creation, we must ensure that the given skin is manufacturable. It is done with Draft Analysis.Like arm rest model this model is also having negative draft.

CLASS B SURFACE:

B Surface of the Bottle holder model is created just by offsetting the Class A surface for 2.5mm. As this model did not have any large curvature areas it will be created fully without any distortion.

DRAFT ANALYSIS OF THE CLASS B SURFACE:

The draft analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.The drafting angle is 2.9 degrees.

CLASS C SURFACE:

C Surface is created by sweeping the edges of Class A surface at 90 degrees with reference surface, where the reference surface was the Class A Surface.it is created by trim the class a and class b surface.

DRAFT ANALYSIS ON THE CLASS C SURFACE:

Using the ‘sweep’ option create the C surface by sweeping the boundary of the CLASS-A surface at an angle of 2.9deg outwards to the tooling direction.

The sweep option need to be performed seperately.it is not possible to create the c surface by a single boundary.

CLASS ABC SURFACE:

class abc surface is created by combining the class a ,class b and class c.while combining the abc surfaces check the gaps between the surfaces.if the gaps are there ,it is impossible to make the closed surface.ABC surfaces are excluded with the additional engineering features.

DRAFT ANALYSIS ON THE CLASS ABC SURFACE:

draft angle is 2.9 degrees.

CLOSED SURFACE OR PART BODY OF THE BOTTLE HOLDER:

this is the final product of bottle holder.it is included with the additional engineering features.flanges are attached to the bottlre holder.

DRAFT ANALYSIS ON THE BOTTLE HOLDER:

draft angle is 2.9 degress.

MULTIVIEW SECTION:

ASSEMBLY OF ALL PARTS AND DEVELIOPMENT OF THE DOOR TRIM PANEL:

STEPS TO MAKE THE ASSEMBLY:

CREATE ASSEMBLY

• Collect the parts inside one assembly (Create a New Product), by either of the options:
• Copy + Paste
• Add Existing Component
• Save Management:
  • We cannot directly save the file by pressing Ctrl+S, because we have to organize the parts in the assembly file folder.

File > Save Management > Select the Parent Product > Save As (Create a separate folder) > Propogate Directly

ADDITIONAL ENGINEERING FEATURES:

these are flanges,heat stakes.push pin,dog houses

FLANGES:

Flanges were created by using the edges of the solid model as a reference. Class A surface of the flange is created by Extruding the edge of the Solid model and the direction of extrusion being the line in the master section. Further sections of the Class A surface were created either by using the “Sweep” option or “Extrude” option. Once the Class A surface is created the Class B surface is created by offsetting it directly and the C Surface is created by using Sweep option. Now all the surface were trimmed and joined together to form a Closed Surface.

flanges are attaches to the all the four parts.

HEAT STAKES AND RIBS:

HEAT STAKES:

Heat stakes are the vertical cylindrical structures added to B surface. These are used to attach the child part with the parent part. This is joined to the parent surface by melting the heat stakes which protrudes beyond the attaching or parent part. This is also called as plastic welding. This kind of attachment provides advantage of avoiding any additional fastening methods like bolting, Push clips etc, which will add the weight of the component. But it has a disadvantage that once it is fixed it cannot be removed without damaging the component. Here since we will not have any need for removing or replacing these parts therefore, we are fixing it with heat stakes. The maintenance works can be done by removing the entire panel itself.

RIBS:

Ribs are the engineering features which are designed with the plastic parts on the B Surface of the part. Ribs are usually designed to improve the strength of the plastic part without increasing the thickness of the component. These ribs were also used to position the part on its parent during assembling.

DOG HOUSES:

Doghouse is a support feature for the other engineering features like locating pins, Screw bosses etc on the B side surface of the plastic component. Whenever these engineering features need to reach the distances of more than five times that of base thickness the feature will become weaker and tend to fail due to the bending moment, to avoid this failure they were mounted over the dog houses where about half of distance will be covered by the doghouse.

PUSH CLIP DESIGN:

Push clip is a part which is used to assemble the plastic parts. It is similar to snap fits where the push clip attached to the child part is pressed against hole in the parent part. Push clip compresses and gets locked inside the hole in the parent part. Unlike heat stakes this method of fastening can be reversed by pulling the child part from the parent part.

PUSH PIN SOLID MODEL:

Solid model of the push clip is created by revolving the sketch with the centre line as its axis. Revolving is done by using Shaft option.Now the push clip is imported into the model and its degrees of freedom need to be arrested to keep the push clip in position.First the Axis of the hole centre in the lower substrate is coincided with the axis of the Push clip which arrests the movements in the X and Z directions.Face of the doghouse top and the push clip face is coincided to arrest the movement along Y Axis.To arrest the rotation of the push clip YZ plane of the push clip and the YZ plane of the lower substrate is offset at distance.