Week 11 - Final project
DEVELOPMENT OF DOOR TRIM PANEL
METHODOLOGY BEHIND 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.
- The door panel has evolved from a simple two-part system of the latch and simple winding mechanism to a more sophisticated enclosure.
- Doors currently have an inner full-width panel consisting of electronic windows, a central locking system, and speakers. These panels typically consist of a foamed core covered with either textiles or plastics.
SOME KEY POINTS OF DOOR TRIM PANEL
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Door panels are expected to meet one of the toughest sets of requirements among interior car components.
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These panels should be designed to withstand and channel loads into the body of the car while being thin (<2 mm).
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These loads could be horizontal and vertical in nature, like the force applied on opening or closing doors while leaning/resting on them or when stepping on the armrest to access the roof.
A GENERAL IDEA OF DOOR TRIM PANEL
BASIC DOOR PANEL DESIGN
THIS IS THE PROVIDED DESIGN WE WILL WORK ON THIS PROJECT
MATERIAL USED FOR PRODUCTION OF DOOR PANEL:-
THE INTERIOR PART OF THE DOOR ASSEMBLY GENERALLY MANUFACTURED BY
- POLYPROPYLENE (PYP)
- ACRYLONITRILE BUTADIENE STYRENE (ABS)
- POLYVINYL CHLORIDE (PVC)
- POLYPHENYLENE ETHER (PPE)
MAJOR COMPONENTS OF DOOR TRIM:-
THESE ARE THE COMPONENTS WHICH WE WORK ON THIS PROJECT-
- UPPER SUBSTRATE
- DOOR ARMREST
- LOWER SUBSTRATE(LOWER)
- MAP POCKETS
TASK TO PERFORM ON THIS PROJECT:-
- CREATION OF TOOLING AXIS
- CREATION OF CLASS A, B, AND C SURFACE
- CREATION OF CLOSED SURFACE OF ALL THE COMPONENTS
- CREATION OF B SIDE FEATURES
- TO PERFORM DRAFT ANALYSIS
TOOLING AXIS CREATION:-
IT IS THE DIRECTION IN WHICH THE CORE AND CAVITY MOVE. WE WILL REQUIRED MULTIPLE TOOLING AXIS FOR EACH COMPONENT . WE WILL ALSO WORK ON THE SIDE CORE AXIS.
WE WILL CREATE A TOOLING AXIS FOR THE ALL THE COMPONENTS.FOR CLEARING THE TOOLINNG AXIS FOR DOOR ARM RESR WE HAV TO USE THE COMPASS AND LOCK THE OREATNATON WHERE THE TOOLING AXIS SHOW THE ALL GREEN IN THE DRAFT ANALYSIS UNDER THE 3 DEGREE ANGLE. AS FOR THE LOWER SUBSTRATE AND MAP POCKET, WE WILL DIRECTLY GO FOT THE NATURAL TOOLING AXIS Y-DIRECTION.
ARM REST 1 
ARM REST 2
LOWER SUBSTRATE .
FOR THE REMAINING COMPONENTS WE WILL CREATE LATER .
DESIGN OF DOOR ARMREST 1 AND 2
CLASS A -SURFACE
FROM THE GIVEN INPUT WE WILL EXTRACT THE CLASS-A SURFACE AND CHECK THE CONNECTIVITY OF CLASS A IF IT IS NOT UP TO THE MARK WE WILL CHECK THE WHOLE COMPONENT ONCE AGAIN.
CLASS B CREATION
class b is generally at the backside of the class a surface and it is the offset part of the class a surface.
CLASS C SURFACE CREATION
IT IS THE EXTRAPOLATED PART OF THE CLASS A SURFACE WHICH IS MADE WITH THE HELP OF SWEEP COMMAND NAD IT CONNECTS THE CLASS A AND B SURFACE.
NOW AFTER CREATING SURFACES A, B AND C . WE WILL GO FOR THE CREATION OF A CLOSED SURFACES.
CLOSED SURFACE
NOW WE WILL GO FOR THE CREATION OF LOWER SUBSTRATE
CLASS A AND CLASS C SURFACE
TRIMMED SURFACE
NOW WE WILL GO FOR THE CREATION OF MAP POCKETS 1 AND 2.
CLASS A SURFACE
CLASS C SURFACE
FINAL SURFACE
CREATION OF B-SIDE FEATURES
B- SIDE FEATURE PLAY A MAJOR ROLE IN PLASTIC COMPONENTS AS THEY ARE THE STRENGTH PROVIDERS TO THE PLASTIC COMPONENTS.
THEY ARE A MEDIUM THROUGH WHICH PLASTIC COMPONENTS CAN ATTACH TO THE SHEET METAL PART.
WITH THE HELP OF THE MASTER SECTION WE WILL CREATE THE B-SIDE FEATURES.
MASTER SECTION IS LIKE SILHOUETTE WITH THE HELP OF THE THAT WE CAN CREATE THE B SIDE FEATURE.
SO THE B SIDE FEATURES FOR THIS PROJECT ARE:-
- DOG HOUSE
- RIBS
- HEAT STEAKS
- FLANGES
DOG HOUSE
IT IS THE ENGINEERING FEATURE THAT IS BASICALLY USED FOR THE SUPPORTING FEATURE. IN THE B-PILLAR PROJECT WE USED 4 WAY LOCATOR ON ITS TOP.BASICALLY, 4 WAY LOCATORS ARE MOUNTED BUT FPR ATTACHMENT STRATEGY WE WILL USE A PUSH PIN.
CREATION OF DOG HOUSE.
NOW WE WILL GO FOR THE CREATION OF HEAT STAKES AND THE RIBS BEFORE THAT WE WILL DISCUSS THE HEAT STAKES AND RIBS.
HEAT STAKES - THESE ARE THE COMPONENTS THAT ARE USED TO JOIN TWO PLASTICS COMPONENTS THAT ARE SIMILAR AND DISSIMILAR.
RIBS- THESE ARE THE COMPONENTS WHICH PROVIDE STRENGTH AND STIFFNESS WITHOUT USING OVERALL THICKNESS. THEY ARE THE FEATURE IN PLASTIC INJECTION MOLDED PARTS.
AS YOU CAN SEE THE HEAT STAKES AND RIBS ARE ATTACHED TO THE LOWER SUBSTRATE. THE HEAT STAKE WILL GOES INTO THE FLANGE AND THEN IT WILL RIVETED.
A GENERAL IDEA ABOUT THE RIVETING.
CREATION OF FLANGE
FLANGES ARE ATTACHED TO THE PART BODY SO IT CAN PROVIDE THE STRENGTH AND SUPPORT TO IT. THE HEAT STAKES GENERALLY GO INTO THE FLANGES WHERE THEY ARE REVITED PROPERLY. THE RIBS ARE THE AREA WHERE THEY RESTED ON IT.
*AS WE FOLLOW THE MASTER SECTION THINGS DOESN'T GO THE RIGHT WAY SO WE HAVE TO MODIFY THE INPUTS OF THE B SIDE FEATURES.
THIS I HAVE TO MENTION BEFORE STARTING THE B SIDE FEATURE BECAUSE IT OCCURS IN THE MAKING OF THE B SIDE FEATURE.
DRAFT ANALYSIS
WHILE CREATING THE CLOSED SURFACE WE ALSO ADD THE DRAFT TO THE PART BODY SO IT CAN EASILY MOVE IN THE DIRECTION OF THE GIVEN DIRECTION. THE MINIMUM DRAFTING ANGLE SHOULD BE 0.5 DEGREES. BY ADDING A DRAFT IT HELPS TO PART BODY TO RELEASE. WITH THE HELP OF TOOLING DIRECTION WE CAN PERFORM THE DRAFT ANALYSIS.
CLASS A COMPONENTS
NOW DRAFT ANALYSIS ON CLOSED SURFACE
AS FOR THE MAIN CLOSED SURFACE, THE DRAFT SHOULD BE 3 DEGREES.
RESULT:-
IN THE END, WE WERE ABLE TO MAKE THE CLASS A, B, AND C SURFACE OF THE RH DOOR PANEL DESIGN. THE DRAFT ANALYSIS HAS BEEN ALSO DONE WHERE IT MEET ALL THE REQUIRED STANDARD.