Week 10 - Challenge 3 - Door Trim Lower with Engineering Features

CREATING 4 WAY LOCATOR AND HEAT STAKE ON DOOR TRIM LOWER PLASTIC COMPONENT.

4 WAY LOCATOR

4-way mean you prevent movement at 2 axes (+X, -X, +Z and -Z) on the plane. We have arrested X and Z plane.

In our case only +Y and -Y the component can move.

HEAT STAKE

• Heat staking is the process to attach two separate components together by melting the base plastic material into a shape that will hold the secondary component.
• Heat stake another word used is plaastic welding.
• In the heat stake melting of plastic under continous pressure forms the head.
• It’s a permanent attachment method that does not require any additional material such as an adhesive or a solvent to make the permanent bond.
• Manufacturing machine can be developed to complete multiple heat staking operations at once to decrease cycle time. The stakes don’t have to be parallel which makes the design options limitless.
• Heat staking is a great option that is comparable in strength and durability to other operations involving secondary fasteners without extra cost. These connections can also resist corrosion in harsh environments.

TOOLING AXIS

YELLOW COLOUR DOTTED LINE IS TOOLING AXIS FOR DOOR TRIM. TO CREATE THIS WE HAVE CREATE A POINT ON THE SURFACE AND USED POINT AND DIRECTION METHOD ALONG THE Y AXIS TO CREATE TOOLING AXIS.

CLASS A SURFACE

CLASS B SURFACE

CLASS C SURFACE

FINAL TRIM

REQUIRED OUTPUT

4 WAY LOCATOR AND HEAT STAKE

Whenever the opposite surface gets attached to the door trim plastic component, firstly the 4 way locator should be in contact with the other component which guides the door trim properly and securely at its position. So we have considered 4 way locator as 25mm from the inner surface of door trim. Heat stake length should be aleast 5mm less than 4 way locatar, so we considered this it as 20mm.

Front View - 4 Way Locator = 2

Heat Stake = 16

STEPS WHICH HAVE BEING FOLLOWED BY ME WHILE DESIGNING THE DOOR TRIM.

TREE STRUCTURE OF DOOR TRIM - CONSTRUCTION

MAIN BODY STEPS OF DOOR TRIM PLASTIC COMPONENT

DRAFT ANALYSIS

• Draft is a taper applied to the faces of the part that prevent them from being parallel to the motion of the mold opening. This keeps the part from being damaged due to the scraping as the part is ejected out of the mold.
• 3 degrees is minimum draft provided to the plastic components.
• In the draft analysis Green colour on the components means the surface is manufacurable and drafted properly according to the tooling axis of the component. Red colour in the opposite means this side comes in mould(core) section cavity.
• To acheive this the compass is being placed on the tooling axis and the component is being selected.
• We use draft analysis in the catia on plastic components to check whether the component is manufacurable or not in the real time industry.

CONCLUSION

Thus we have successfully designed 4 Way Locator and Heat stakes on the given door trim plastic component.