FINAL PROJECT: DOOR TRIM PANEL DESIGN & ASSEMBLY

OBJECTIVE: This report aims to document the design and development process of a Door Trim panel, adhering to industry standards and best practices. The objective is to create a CAD model with a thickened part, mounting features, and attachment strategy, including Push pins with Doghouse and heat stakes, while considering material details, draft analysis, tooling analysis, and parting lines to ensure efficient and smooth production. The output will serve as a valuable reference for future production and maintenance of the Door Trim panel. 

 

INTRODUCTION:

The purpose of this report is to document the process of designing and developing a Door Trim panel, which involves creating a CAD model, selecting an attachment strategy, determining material details, conducting draft analysis, tooling analysis, and defining parting lines. The objective is to provide a comprehensive overview of the design and development process that adheres to industry guidelines and master sections. The report will include a detailed description of the attachment strategy, which includes using Push pins with a Doghouse for Lower substrate – Door panel attachment and heat stakes for part-to-part attachment. The output will be a thickened part that follows master sections for reference, mounting features that adhere to design guidelines, and a CATpart and CAT product for reference. Additionally, the report will cover draft analysis and tooling analysis, as well as the creation of parting lines and a feasibility check for tooling. Overall, this report aims to provide a detailed and comprehensive overview of the development process for a Door Trim panel, following industry standards and best practices.

ATTACHMENT STRATEGY:

The Door Trim panel's attachment strategy involves Push pins with Doghouse for the Lower substrate – Door panel attachment and heat stakes for part-to-part attachment. This method provides a secure and stable attachment that is resistant to vibration and shock, meeting the industry's safety requirements. The attachment strategy also allows for easy assembly and disassembly during the manufacturing and repair processes, which contributes to cost savings and efficient production.

MATERIAL DETAILS:

The Door Trim panel's material details must meet the industry's safety and performance requirements. A high-quality and durable material that can withstand impact and wear is necessary. The use of materials such as ABS or PC-ABS blends is recommended, as they offer excellent impact resistance, stiffness, and durability while being cost-effective. The material selected for the Door Trim panel must also comply with environmental regulations and meet industry standards for flame resistance.

DRAFT ANALYSIS:

Draft analysis is an essential part of the design process, as it ensures that the Door Trim panel can be manufactured efficiently. The analysis determines the draft angle required to remove the part from the mould without damaging it. The draft angle should be at least 1 degree to ensure a smooth and easy release from the mould. The analysis also checks for undercut, which is the portion of the part that would become trapped in the mould during the moulding process. If an undercut is detected, it must be eliminated or redesigned to ensure efficient and smooth production.

TOOLING AXIS ANALYSIS:

Tooling analysis is another critical aspect of the design process, as it determines the feasibility and cost-effectiveness of manufacturing the Door Trim panel. The analysis includes selecting the moulding process, such as injection moulding or compression moulding, determining the tooling cost and lead time, and evaluating the mould's design for efficient production. The tooling analysis must also ensure that the Door Trim panel's design adheres to the industry's safety and performance standards.

PARTING LINES:

Parting lines are the areas where the mould separates to release the moulded part. The creation of parting lines is essential to ensure that the Door Trim panel can be efficiently and effectively manufactured. Parting lines must be carefully placed to avoid creating areas that could trap air or cause cosmetic defects in the finished product. The parting lines must also be designed to ensure the proper fit and function of the Door Trim panel, adhering to the industry's safety and performance standards.

CONCLUSION:

In conclusion, the design and development process for a Door Trim panel requires careful consideration and adherence to industry guidelines and best practices. The attachment strategy, material details, draft analysis, tooling analysis, and parting lines must be carefully designed and analyzed to ensure efficient and cost-effective manufacturing while meeting the industry's safety and performance standards. The output should be a thickened part that follows master sections for reference, mounting features that adhere to design guidelines, and a CATpart and CAT product for reference. The use of Push pins with a Doghouse for Lower substrate – Door panel attachment and heat stakes for part-to-part attachment is recommended for a secure and stable attachment that is resistant to vibration and shock. Materials such as ABS or PC-ABS blends are suitable for the Door Trim panel, as they offer excellent impact resistance, stiffness, and durability while being cost-effective. Draft analysis and tooling analysis are crucial in ensuring efficient and smooth production while parting lines must be carefully placed to avoid creating areas that could trap air or cause cosmetic defects in the finished product.

Overall, this report provides a comprehensive overview of the design and development process for a Door Trim panel, following industry standards and best practices. By considering the attachment strategy, material details, draft analysis, tooling analysis, and parting lines, designers and manufacturers can create a high-quality and durable Door Trim panel that meets the industry's safety and performance standards while being cost-effective to produce. The report's output, including the thickened part, mounting features, and CATpart and CATproduct, provides a valuable reference for future production and maintenance of the Door Trim panel.

 

MAIN REPORT:

CLASS A SURFACES THAT ARE PROVIDED TO US :

1. ARMREST: 

 

2. LOWER SUBSTRATE: 

 

3. MAP POCKET:

 

4. BOTTLE HOLDER:

 

WHEN ALL OF THEM ARE VIEWED TOGETHER:

 

Now, we will begin by checking the State of Connectivity for the Class A Surface and ensure no gaps between the surfaces as all the surfaces should be joined well together and shouldn't consist of any discontinuities between them.

 

There are two methods to inspect the State of Connectivity for the Class A Surface:

1. Using the 'Join' Command' from the 'Operations Toolbar': 

First, we'll click on 'Join Command' and select our Class A Surface. Then, we have to ensure that the 'Check Connexity' option is marked as shown in the images below. It will check for any gaps that may be present between our surfaces. Then, we'll click on the 'Preview' button and if it doesn't show any 'Connexity Error' on our surface then it means our surface is well-connected and there are no discontinuities between it.

 

2. Using the 'Boundary' Command' from the Operations Toolbar:

In this case, we have to click on the 'Boundary' command and then select the Class-A Surface. After that, we'll click on the 'Preview' button to highlight all the boundaries on the Class-A surface and check if there are any internal boundaries other than the outer edge. 

 

In our case, there are no 'Connexity Errors' for the given Class A Surfaces except in the Arm Rest's Class A Surface.

In case there is a 'Connexity Error', we can fix it by increasing the 'Merging-Distance' up to 0.003mm following the industry standard or we can perform other operations such as Extract, Trim, Join, etc. 

Here's the boundary error that we came across in the Arm Rest's Class A Surface. As we can notice from the image the boundary has extended to the interior section of the Arm Rest which is undesirable as we want to keep the along the outer edges only. Hence, now we're going to fix it. 

NOTE: If there's an issue with the Class A Surface, firstly, we're required to report it to the Class A Surface Design Team first and let them know about the issues that we're facing with the Class A Surface and let them recreate or fix those surfaces but this is only possible in an industrial setting and our case, we're going to fix this on our own for now and proceed with the project. 

 

Then, we found another issue with the Class A Surface where it has an edge protruding out which will lead to poor offset while creating the Class B Surface and hence we're going to fix it using some operations.  

In the above image, we can notice that the filleted surface has been removed and a Spline was created that will be used to cut the protruding section using the Split Command as shown in the following image below.

After that, we're going to create the necessary tooling axes for the Arm Rest Component using appropriate methods used in the industry such as bisecting method or choosing the direction from which the maximum amount of surface is visible for the component to be created. 

In the image above, we can see that there are two tooling axes, one is the Main Tooling Axis and the other one is the Side Core Tooling Axis. In the plastic industry, a Side Core Axis is used along with the Main Tooling Axis to create specific components because it allows for creating features that cannot be produced with a single tooling axis.

The side core axis is typically used to create undercuts or recessed features in the plastic part. An undercut is a feature that cannot be made using a single tooling axis because it would require the tool to cut in the opposite direction of its entry point. By using a side core axis, the tool can be moved in multiple directions, allowing for the creation of undercuts.

In contrast, the main tooling axis is typically used to create the bulk of the plastic part. It moves in a linear motion and is used to shape the overall form of the part.

While it is possible to create some parts using a single tooling axis, certain parts with complex features or undercuts may require the use of a side core axis. Using only one tooling axis may result in a part that is incomplete or does not meet the desired specifications.

Overall, the use of a side core axis along with the main tooling axis allows for greater design flexibility and the creation of more complex plastic parts.

 

Even though undercuts can increase the complexity of creating a plastic component, in some cases, they are necessary or desirable for the functionality or appearance of the part.

For example, an undercut can be used to create a snap-fit feature in a plastic part, allowing it to securely attach to another component. Undercuts can also be used to create decorative features, such as grooves or patterns, on the surface of a part.

While undercuts can increase the complexity of the manufacturing process, modern manufacturing techniques such as multi-shot moulding and over-moulding have made it easier and more cost-effective to produce parts with undercuts.

In addition, the benefits of having undercuts in certain parts may outweigh the added complexity and cost of production. For example, a snap-fit feature created by an undercut may eliminate the need for additional hardware or assembly steps, reducing the overall cost and complexity of the final product.

Overall, the decision to include undercuts in a plastic part is a trade-off between the benefits and the added complexity and cost of production. In some cases, the benefits of having undercuts may outweigh the additional complexity and cost, making it worthwhile to include them in the design of the part.

 

DRAFT ANALYSIS ON THE CLASS A SURFACE:

Next, We will perform a Draft Analysis on the Class A Surface itself:

Before starting with a Draft Analysis Operation, we will go to the 'Customize View Parameters' option under the 'View Toolbar'. Then we will enter the 'Customize View Mode' where we will go under the 'Mesh' option and select 'Material' and press 'OK'. 

To start the Draft Analysis in the 'Generative Surface Design Workbench', we will go to 'Insert' and then look for the option called 'Analysis'. Once found, we will go under that and click on 'Feature Draft Analysis. This will open the 'Draft Analysis' Dialogue box. There, we will ensure that under 'Mode'  we have selected 'Quick Analysis', under 'Display' we will select 'Show or Hide the Color Scale' and then select '3 Degrees' as the permissible draft angle. Then, under 'Direction' we will choose the icon with the symbol of the compass on it which stands for 'Use the Compass to define the new current draft direction'.

Draft analysis on the Class A surface is important in the design and manufacturing of plastic parts because it helps to ensure that the parts can be successfully produced and meet the required specifications.

Draft analysis is the process of checking the angle of a surface in relation to the direction of the mould opening. In plastic injection moulding, the mould is opened in a specific direction to release the part from the mould. If a surface on the part is parallel to this direction, it can create a vacuum effect that makes it difficult or impossible to remove the part from the mould.

By analyzing the draft angles on the Class A surface of the part, designers can ensure that the part will release smoothly from the mould without damaging the surface finish. This is particularly important for parts with complex geometries or textured surfaces where maintaining a high-quality finish is critical.

Additionally, proper draft angles can help to prevent other defects such as sink marks or warpage that can occur if the plastic material is not able to flow evenly during the moulding process.

Ultimately, performing draft analysis on the Class A surface can help to ensure that the part is designed for manufacturability, minimizing the risk of costly errors or delays in production.

With respect to the Main Tooling Axis: 

With respect to the Side Core Axis: 

From the Draft Analysis above, we can certainly conclude that our Class A Surface needs further modifications to ensure that our component meets its Draft Angle requirements of 3 degrees but as of now, we're going to proceed with it. 

 

PROCEDURE TO CREATE THE CLASS B SURFACE:

We'll offset the Class A Surface by 2.5mm as shown below:

From the above image, we can see that it is not offsetting properly as some sub-elements of the surface will become erroneous which means they'll not get offsetted and hence we've to recreate them using various tools. I used Multi-Section Surface to fix this issue as shown below:

We'll join this surface with the Main offset surface. I found another problem with the surface as shown below and I'll fix it using various commands such as Extract, Extrapolate, Sweep, Trim, etc.  

Fixed Surface: 

 

PROCEDURE TO CREATE THE CLASS C SURFACE:

To generate the Class C Surface, the initial step is to unhide the Class A Surface and extract its boundaries using various commands. Among these, the Sweep Command with Draft Direction and Reference Surface is of utmost importance, as it allows us to create the desired surface by our requirements. Once the Class C Surface is created, we can merge it with the Class A Surface to form a single entity.

 

Next, we plan to merge the Class C Surface with the Class A Surface and create an intersection between the two with the Class B Surface. This will enable us to assess the feasibility of a Trim Operation between them. However, upon evaluation, we may find that the current intersection is not viable. In such cases, we will extend the Class B Surface and re-evaluate the feasibility of the Trim Operation.

To identify any issues with the intersection, we can utilize the Disassemble Command located under the Operations Toolbar. This will allow us to pinpoint any problem areas and rectify them accordingly.

Upon successfully executing the Trim Operation, we will obtain a closed hollow body for the Arm Rest Component. To ensure that it is entirely enclosed, we will employ the Boundary Command. If the command fails to create a boundary around the body, it indicates that we have a completely closed body.

Subsequently, we will switch to the Park Workbench and utilize the Closed Body Command to convert the closed body into a Solid Body.

 

FINAL CLOSED BODY FOR THE ARMREST: 

 

DRAFT ANALYSIS ON THE ARMREST'S CLOSED BODY:

NOTE: Class A Surface is needed to be modified as there are several places where it is creating issues and cannot be recreated. 

 

 

 

Now, we'll create solid bodies for other components as well such as for Lower Substrate, Map Pocket and Bottle Holder as shown below:

 

FINAL CLOSED BODY FOR THE LOWER SUBSTRATE: 

 

DRAFT ANALYSIS ON THE LOWER SUBSTRATE'S CLOSED BODY:

 

 

 

FINAL CLOSED BODY FOR THE MAP POCKET: 

 

 

 

 DRAFT ANALYSIS ON THE MAP POCKET'S CLOSED BODY:

 

 FINAL CLOSED BODY FOR THE BOTTLE HOLDER: 

 

 

 

 DRAFT ANALYSIS ON THE BOTTLE HOLDER'S CLOSED BODY:

Upon examining the Draft Analysis of the Bottle Holder depicted in the above image, it is evident that a particular section of the body does not clear the Main Tooling Axis as intended. To address this issue, we must coordinate with the Class A Surface Design Team to modify the surface by the required draft angle.

It is crucial to note that the parting surface should always be created on the Class B Surface rather than the Class A Surface. This is because certain defects, such as a Flashing Defect, can occur during manufacturing. Suppose such a defect arises on the Class A Surface. In that case, it will compromise the surface finish and necessitate the use of additional cutting tools to remove the excess material, resulting in a less desirable outcome. By placing the parting surface on the Class B Surface, the manufacturing department can conveniently eliminate the excess material without affecting the visible Class A Surface.

 

PROCEDURE TO CREATE NECESSARY ENGINEERING FEATURES:

1. HEAT STAKES

2. LOCATORS

3. DOGHOUSES  

 

The above image showcases numerous engineering features incorporated into the design of the Door Trim to streamline the assembly process. Although the depicted components may differ from our own, this serves as an example of what our final product may resemble.

 

ROLE OF HEAT STAKES & LOCATORS IN THE PLASTIC DESIGN INDUSTRY:

Heat stakes and locators are commonly used in the plastic design industry to join plastic parts together, particularly in the automotive and electronics industries. Heat staking is a process of melting a small section of plastic and then forming it into a boss or protrusion to create a joint with another plastic part. Locators, on the other hand, are used to position and hold plastic parts in place during assembly.

Heat stakes are created by using a thermal tool to melt a small section of the plastic part, typically in the shape of a boss or post. The melted plastic is then formed into a protrusion or raised feature that can be used to create a joint with another plastic part. This process is often used for creating snap fits, which are designed to hold two parts together without the need for additional fasteners.

Heat staking can also be used to create airtight seals between plastic parts, as well as for inserting metal or plastic components into a plastic part. The process is relatively fast and inexpensive compared to other joining methods, making it a popular choice in industries where speed and cost are key factors.

Locators are used to position and hold plastic parts in place during assembly. They are typically small features on a plastic part that fit into corresponding holes or slots on another part, allowing for precise alignment during assembly. Locators can also be used to provide additional stability and support for plastic parts.

Overall, heat stakes and locators are important tools in the plastic design industry, allowing for efficient and cost-effective assembly of plastic parts. By using these techniques, designers can create strong, precise, and reliable joints between plastic parts, making them suitable for a wide range of applications.

 

ROLE OF DOGHOUSE IN THE PLASTIC DESIGN INDUSTRY:

In the plastic design industry, the term "doghouse" typically refers to a raised area on a plastic part where heat stakes or locators are inserted. Heat stakes are small plastic studs that are heated and pressed into the doghouse to create a secure connection between two plastic parts. At the same time, locators are cylindrical posts used to align parts during assembly properly.

The doghouse provides a dedicated area on the plastic part for the heat stake or locator, allowing for precise placement and ensuring that the connection is secure. The raised area of the doghouse also helps to prevent the heat stake or locator from deforming the surrounding plastic during insertion.

Designing a doghouse involves determining the optimal size and shape for the heat stake or locator, as well as the placement and orientation of the doghouse on the part. Proper design and placement of the doghouse can help ensure the integrity and functionality of the assembled product.

Overall, the doghouse is an important element in plastic part design that facilitates the use of heat stakes and locators for secure and accurate assembly.

 

 

I will design an attachment strategy for the door trim by incorporating heat stakes, locators, and doghouses. These features will facilitate the assembly of various components with the door trim, including sheet metal components or other required parts.

To visualize this attachment strategy, I have included an image below. Generally, components such as switches, speakers, wiring harnesses, and airbag modules are added to the door trim plastic component.

It is crucial to ensure that the attachment strategy is implemented with precision and accuracy, as any flaws or inconsistencies could compromise the functionality and safety of the final product.

 

The STP file contains four Master Sections that will serve as our reference while designing the engineering features. While we will strive to follow these sections as closely as possible, they do not provide all the necessary details. For instance, the draft angle is not specified for these attachment features, and one of the master sections is placed incorrectly.

Therefore, we will use the Master Sections as a guide, but also incorporate our own design considerations to ensure the engineering features are appropriate for our needs. We will take into account the required draft angles and make necessary adjustments to the placement of the master section to align with our design requirements. By doing so, we can ensure that the final product meets our specifications and is suitable for its intended purpose.

 

MASTER SECTION ONE: 

 

MASTER SECTION TWO:

 

MASTER SECTION THREE:

 

MASTER SECTION FOUR:

 

PROCEDURE TO CREATE A HEAT STAKE:

In order to facilitate the assembly process with the Arm Rest, Map Pocket, and Bottle Holder, we will be designing all the required engineering features on the Lower Substrate. Following the provided master section, we will create planes and projection points, and construct sketches to generate the necessary heat stakes and locators. These features will enable a seamless integration of the Lower Substrate with its counterparts, ultimately contributing to the successful assembly of the entire component.

Initially, a projection point was established using the print command with the 'Point Type' parameter set to 'Between'. Subsequently, the two lowermost points of the master section were selected to construct the projection point. To create the sketch plane, the 'Line Command' was employed with the 'Line Type' parameter set to 'Normal to the Curve'. The Main Tooling Axis of the Lower Substrate was selected as the curve, and the projection point was utilized to define the plane.

Following the creation of the projection point and plane, we proceeded to generate two positioned sketches, serving as a basis for creating the Heat Stake and Ribs. The diameter of the heat stakes was determined through the use of the measure tool on the master section, and the ribs were created while considering the diameter of the heat stake. The resulting sketches are depicted in the accompanying image.  

Subsequently, we referred to the Master Section to calculate the height of the Heat Stake. Moving forward, in the Part Workbench, we selected the Pad Command to pad the sketch with the determined height limit. Further, we performed the Pad Operation on the ribs, taking into account the diameter of the heat stake. We added the necessary Draft, Fillet, and Chamfer values to make the ribs feasible for manufacturing along with the heat stakes.

 

To ensure seamless integration between the heat stakes and the lower substrate, we have added a second limit of 2mm or more. This will allow us to remove any protruding material from the lower section of the substrate by performing a Union Trim Operation.

Upon examination, we found that the walls of the ribs were present inside the heat stakes, which is not an optimal design. To rectify this issue, we performed a Union Trim Operation to remove the undesired walls. Furthermore, we conducted a Draft Analysis to confirm that the engineering features adhere to the required draft angle of 0.5 degrees.

 

 

 AFTER UNION TRIM OPERATION: 

 

DRAFT ANALYSIS ON THE HEAT STAKE:

 

 

DRAFT ANALYSIS ON THE HEAT STAKE'S RIBS:

In order to create additional Heat Stakes and Locators, a curve was extracted and the Parallel Curve Command was used to offset it at a specified distance. The Points & Planes Repetition Command was then used to generate multiple points on the resulting curve, as illustrated in the images below. The distance between each point was set to 50mm, as this is the minimum separation requirement for our engineering features

As depicted in the image above, the blue line represents the curve that was extracted using the Multiple Extract Command, while the yellow line represents the Parallel Curve created using the Parallel Curve Command. The distance between each of the points created on the curve is 50mm, as per the minimum separation requirement between two engineering features.

 

PROCEDURE TO CREATE A LOCATOR:

Now, we're going to create a locator. When designing a locator, one of the most crucial design rules is to ensure that it has a greater height than other engineering features. This is because the locator plays a critical role in accurately arresting the component during assembly, ensuring that other engineering features are placed in their correct positions. By increasing the height of the locator, we can ensure that it comes into contact with the component first, enabling it to be precisely arrested during the assembly operation.

SKETCH FOR THE LOCATOR:

 

 

PAD OPERATION:

 

 

APPLYING DRAFT ANGLE W.R.T THE NEUTRAL ELEMENT:

  

THE UPPER EDGE OF THE LOCATOR SHOULD HAVE A MINIMUM LENGTH OF 0.75MM OTHERWISE IT CAN COMPROMISE ITS STRUCTURAL INTEGRITY. 

 

 

THEN, A 3MM 45-DEGREE CHAMFER IS APPLIED TO THE SELECTED EDGES AS SHOWN BELOW:

 

 

FINALLY, AN EDGE FILLET VALUE OF 0.25MM IS APPLIED: 

 

 

DRAFT ANALYSIS ON THE LOCATOR:

 

Now, After creating both the Heat Stakes & the Locator, we're going to use the Translate Command in the Part Workbench to translate these Engineering Features to their desired location of the Lower Substrate as shown below: 

  

 

 

PROCEDURE TO CREATE THE DOGHOUSE: 

Following the previous step of positioning the planes, we created sketches for the sidewalls of the doghouses and extruded them to achieve the desired height. Using the multi-sections command, we then created the top wall of the doghouse and combined it with the sidewalls using the 'Join' operation to obtain the complete doghouse structure. These steps were taken in accordance with the design guidelines to ensure proper functionality and alignment of the doghouses on the lower substrate component.

Following the completion of the doghouse structure, we then moved on to the Park Workbench and utilized the Thick Surface Command to create the initial phase of the doghouse, as illustrated in the image below. This involved modifying the surface thickness to meet the desired specifications, in order to ensure optimal functionality of the doghouse in its intended application.

The next step in creating the doghouses involves performing a Coring Operation, which entails creating the base of the doghouse in the Surface Workbench using the Multi-Sections Command. This base is then offset by a specific height in accordance with the design rules. Next, we extract all of the sidewalls of the doghouse and join them with the offset base wall. Finally, we extrapolate the structure to the appropriate location for the Split Operation using it in the Park Workbench. These steps were executed systematically to ensure proper alignment and functionality of the doghouses, as depicted in the image below.

 

 

AFTER UNION TRIM WITH THE LOWER SUBSTRATE: 

 

PROCEDURE TO CREATE THE COUNTERPARTS (FLANGES): 

To begin with, our objective is to produce the flanges for the Arm-Rest Component, adhering to the Master Section guidelines for each specific part in relation to the Lower Substrate. As illustrated below, our first step in achieving this is to extract the C-Surface from the Final Trim between Class A+C and B.

Next, we will utilize the Master Section to generate a plane using the Three Point Command. This plane will intersect with the previously extracted C-Surface, enabling us to establish the intersection point. Ultimately, this intersection point will serve as a crucial reference point for creating the flanges with respect to the Lower Substrate. The visual representation of the plane and intersection point is depicted below.

Then, we'll extract the boundary from the extract c-surface that can be used as a guide curve eventually to create surfaces for these flanges. 

Then, we're going to create two sketches with respect to the master section as shown below:

 

 

To proceed, we will utilize the Sweep Command and choose the 'With Reference Surface' subtype. We will then select the sketch that originates from the intersection point we previously established, and employ the extracted c-surface boundary as our guide curve to generate a surface. The resulting outcome is demonstrated below.

 

We're then going to use the 'Extrude' command to the other sketch to create a surface as shown below: 

We'll then trim them with each other to obtain the surface as shown below:

Then, we'll use the Thicken Command on the trimmed surface from the Part Workbench as shown below: 

Our subsequent step involves extruding the sketch in a distinct direction, which will enable us to produce a surface capable of splitting the previously created trimmed surface. This surface will then be offset to a designated distance in accordance with our flange design guidelines, and subjected to the split operation to generate a surface that can be employed in the thickened command of the part workbench, thereby facilitating the creation of the initial phase of our flange.

 

We'll create a Multi-Sections Surface and join it with the offsetted surface to use that for the split operation in the Park Workbench as shown below:

We are now going to perform a draft operation on the Arm-Rest Component along its side core axis, as illustrated in the diagram below. This will involve making changes to the component's shape to create a tapered or angled surface.

 

After that, we're going to Edge-Fillets to it as shown below:

 

Now, we are going to perform the union-trim operation between the flange and the arm-rest component to merge it with the main component as shown below:

As seen in the image above, the flange is almost complete except for the hole that needs to be created to allow for the heat stake to pass through it. The hole should have a clearance of 0.5mm on each side and a total clearance of 1mm. To achieve this, we will create new planes and use them to make sketches for the counter hole.

As shown in the previous image, we applied a pad operation to the sketch created for the counter hole. Next, we will add a draft to this surface as well. This draft will involve making slight changes to the surface's angle or slope to create a tapered or angled feature.

In the final step, we will use the Boolean operation 'Remove' to eliminate the padded body from the flange, resulting in a hole. This hole will also follow the draft direction of the main tooling axis, creating a tapered feature that matches the design specifications.

 

DRAFT ANALYSIS ON THE FLANGE:

For the flange, we're using different axes for the flange and the counter-hole. 

 

 

 

DRAFT ANALYSIS ON THE COUNTER-HOLE:

Using the same approach, we will create the remaining flanges while ensuring that they're following the draft direction. It is not possible to simply translate the initial flange to other positions, so we will need to create each one individually. All of the flanges, created using this method, can be seen in the image below.

 

 

DRAFT ANALYSIS ON ALL THE FLANGES:

 

 

 

 DRAFT ANALYSIS ON ALL THE COUNTER-HOLES:

 

 

CONSTRUCTION OF FLANGES FOR THE MAP POCKET:

We created flanges for the Map Pocket using similar methods as shown below: 

 

DRAFT ANALYSIS ON THE FLANGES FOR THE MAP POCKET:

 

 

DRAFT ANALYSIS ON THE FLANGES FOR THE COUNTER-HOLES:

 

 

CONSTRUCTION OF FLANGES FOR THE BOTTLE HOLDER:

 

DRAFT ANALYSIS FOR THE FLANGES OF THE BOTTLE HOLDER:

 

 

 

 

 DRAFT ANALYSIS FOR THE COUNTER-HOLES OF THE BOTTLE HOLDER:

 

 

 

 

To facilitate the identification of the individual flanges, each has been assigned a specific colour code corresponding to a particular part. This allows for easy differentiation and tracking of the various flanges, ensuring that they are correctly assigned to their respective components.

 

 

PROCEDURE FOR ASSEMBLY OPERATION:

In the final step of the assembly process, we will utilize the Assembly Workbench to bring all of the individual components together. We will start by creating a point and using the Coincidence Constraint from the Constraints Toolbar to ensure that the components are assembled precisely and accurately. This will guarantee that the final product will function seamlessly, without any misalignment or errors.

Furthermore, we have been provided with a Push Pin body that needs to be seamlessly integrated into the Keyhole on the Doghouse. Using the same set of tools, we will carefully assemble the Push Pin into the Keyhole to ensure that it fits securely and functions properly. This will be a crucial step in the assembly process, as it will determine the overall stability and durability of the final product.

PUSH PIN:

 

 

PUSH PIN ASSEMBLY:

 

 

 

To verify that all of the components have been properly constrained, we will utilize the Move Toolbar and the Manipulation Command. This command enables us to move the components along the X, Y, or Z-axis, according to our preferences. Once we have moved the components, we will click on the Manual Update button to see if they align in their respective positions as per our initial constraints.

This step is crucial to ensure that all the components have been constrained correctly and will function seamlessly when assembled. It provides an extra layer of assurance that the final product will work flawlessly without any issues. By carefully manipulating and verifying the position of each component, we can guarantee the high quality and reliability of our final product.

 

KEYSHOT RENDERING FOR THE FINAL FILES: