Week 11 - Final project

AIM: To develop a door trim panel using given class A surface with the help of given master sections.

OBJECTIVE:

1. To join the unconnected surfaces to its respective subparts and import them into assembly workbench.
2. To perform draft analysis of the individual component by creating a proper tooling axis for each component.
3. To create a solid part model by creating class B and C surface from given class A surface.
4. To create appropriate engineering features on the B surface.

INTRODUCTION

Fig 1: Typical inner panel of car door (www.fes-aes.de)

A car door is a complicated module made up of a number of fixed and movable subassemblies and components. Safety, vehicle dynamics, aesthetics, and strength are all important factors to consider while building the door assembly. Apart from the foregoing, door trim should be designed to reduce BSR (buzz, squeak, and rattle) during vehicle operation (Sahoo.M., Langfei. R., et al, 2017 ). Figure 1 shows a typical inner panel of car door.

A car door trim panel has different components and sub assemblies. Four important components developed in this project are listed below and as shown in figure 2.

1. Arm rest.
2. Lower substrate.
3. Lower map pocket.
4. Upper map pocket.

Fig 2: Lower door trim panel

An unconnected class A surface along with master sections are provided as shown in figure 3.

Fig 3: Input class A surface with master sections

Above shown class A surface is joined using join command with all appropriate surfaces to its respective components as shown in figure 4.

Fig 4: Joined surfaces

Figure 5 shows the different engineering features to be created in the B side according to master section given.

Fig 5: Illustration of master section

Given surface data is imported into assembly workbench as shown in figure 6. A top down approach is used in this study.

Fig 6: Surface data in assembly work bench

DRAFT ANALYSIS OF CLASS A SURFACE OF INDIVIDUAL COMPONENTS

Draft analysis is performed on the component to analyse whether the component is provided with the sufficient draft, to make it east to remove from the mold while ejecting the component. Figure 7 shows the component with and without draft. Tooling axis the direction along which core and cavity seperates.

Fig 7: Component with draft and without draft

Arm Rest

Figure 8 shows the class A surface with main tooling axis and side core axis.

Fig 8: Arm rest class A surface with tooling axis

Fig 9: Draft analysis of arm rest along main tooling axis

Surfaces in green color are cleared by main tooling axis as shown in figure 9. For the areas in red we need to consider a side core axis as shown in figure 10.

Fig 10: Draft analysis of arm rest along side core axis

Lower Substrate

Figure 11 shows the class A surface of lower substrate and as shown in figure 12 the tooling axis clears the lower substrate.

Fig 11: Lower substrate with main tooling axis

Fig 12: Lower substrate draft analysis

Lower Map Pocket

Figure 13 shows the class A surface of lower map pocket with tooling axis. As shown in figure 14 the tooling axis clears all the concerned surfaces, area highlighted in red has a -10 deg draft which needs to be escalated to the surface design team.

Fig 13: Lower map pocket class A surface with tooling axis

Fig 14: Lower map pocket class A draft analysis

Upper Map Pocket

Figure 15 shows the upper map pocket with tooling axis. As shown in figure 16 the surface has sufficient draft along the tooling axis which is 3 degree in this project.

Fig 15: Upper map pocket with tooling axis

Fig 16: Upper map pocket draft analysis

CREATION OF SOLID MODEL WITH ENGINEERING FEATURES

Arm Rest

As the name suggests arm rest is used as an aesthetic feature and its sole purpose is to rest the arm and have power window buttons. Figure 17 shows the surface model of the arm rest and figure 18 shows the solid model of the arm rest with engineering features. Thermal staking provides an alternative to welding when the two parts consist of dissimilar materials which cannot be welded or when simple mechanical retention of one part relative to another is adequate.

Fig 17: Closed surface model of arm rest

Fig 18: Solid model with engineering features

Fig 19: Arm rest with heat stake

Fig 20: Arm rest with flange

Fig 21: Heat staking

Fig 22: Door arm rest master section

Upper Map Pocket

Figure 23 shows the closed surface model of upper map pocket and figure 24 shows the solid model upper map pocket.

Fig 23: Closed surface model of upper map pocket

Fig 24: Solid model of upper map pocket with engineering features

Lower Map Pocket

Figure 25 shows the closed surface model of lower map pocket and figure 26 shows the solid model of lower map pocket with flanges.

Fig 25: Closed surface model of lower map pocket

Fig 26: Solid model of lower map pocket with flanges

Lower Substrate

Figure 27 shows the closed surface model of the lower substrate and figure 28 shows the solid model of lower substrate.

Fig 27: Closed surface model of lower substrate

Fig 28: Solid model of lower substrate with engieering features

Fig 29: Lower substrate with heat stake and locator

Fig 30: Lower substrate with dog house and push pin

Fig 31: Draft analysis of lower substrate engineering features

Fig 32: Lower substrate draft analysis of dog house and heat stake

Fig 33: Door trim with engineering features

CONCLUSION

A door trim panel using given class A surface with the help of given master sections has been developed by following steps

1. To join the unconnected surfaces to its respective subparts and import them into assembly workbench.
2. To perform draft analysis of the individual component by creating a proper tooling axis for each component.
3. To create a solid part model by creating class B and C surface from given class A surface.
4. To create appropriate engineering features on the B surface.