DESIGN OF CAR DOOR INTERIOR TRIM

DEVELOPMENT OF A DOOR TRIM PANNEL

AIM: To Create a CAD model considering the following inputs as like in OEM and tier1 companies

1. Class A surface
2. Nominal thickness with reference of Master Sections
3. Attachment strategy

INPUT:

1. Class A Surface
2. Master Sections

STEPS INVOLVED:

• TOOLING AXIS
• SURFACE THICKNESS
• ATTACHMENT CREATION
• DRAFT ANALYSIS 
• TOOLING FEASIBILITY CHECK

PROCEDURE:

Imported the Given File in the Catia

Opened Assembly Workbench and Imported the Parts to the Assembly

they are Bottom Substrate, Map Pocket, Door Arm Rest

1. TOOLING AXIS:

A. Lower Substrate:

The given input of the Lower Substrate is as shown in the figure.

• Developed the Class A surface according to the given Master Sections.
• The Tooling Direction For the Class A Surface is found out.

B. Map Pocket:

• The Given Input  Contains Master Sections and Surfaces.
• According to the Master Sections, Class A is developed with Flanges.
• The Tooling Direction for the Given part is not possible. 
• So that, The Part is divided into two parts.
• Tooling Direction for each part is created.

Given Input:

Tooling Axis:

C. Arm Rest:

Input:

• The Given Input  Contains Master Sections and Surfaces.
• According to the Master Sections, Class A is developed with Flanges.
• The Tooling Direction for the Given part is not possible. 
• So that, The Part is divided into two parts.
• Tooling Direction for each part is created.

 

2. THICKENED PART:

1. Class-A Creation & Class-B Surfaces:

a. Lower Substrate:

 

 

                                        Class A Surface                                                           Class B Surface

 b. Map Pocket:

 

c. Arm Rest:

 

2. Class-C Surface:

Class C surfaces are created based on the tooling direction as well surface reference.

Tools used:

Creating Swept surfaces: The swap tool is provided to create surfaces by sweeping a profile along a guide curve in the Wireframe and Surfaces Design workbench of CATIA V5.

Creating Swept surfaces with draft direction: similar to the Creating Swept surfaces but we have to select a direction for the draft.

Creating Lofted Multi-Section Surface: This tool allows the creation of lofted multisection surfaces. The surface is created between the sections along the computed or user-defined spline. 

Creating Blended Surfaces: This tool allows to the creation of a surface by blending two curves. These curves can be sketched curves, wireframe geometries, or edges of existing surfaces.

 

                      BOTTOM SUBSTRATE

 

                              MAP POCKET PART-1                                                      MAP POCKET PART-2

 

                       ARMREST PART-1                                                                    ARMREST PART-2

 

3. Final Trims:

Trimming class A, with class C and Class A + C with Class B. using Trimming Surfaces Insert > Operations > Trim

The Trim tool allows trimming two intersecting surfaces or curves with respect to each other.

 

Closed Trims:

 

                             BOTTOM SUBSTRATE                                                                            MAP POCKET PART-1            

 

                                          MAP POCKET PART-2

 

  

                                      ARMREST PART-1                                                                    ARMREST PART-2

 

Closed Body:

Convert all closed surfaces to solids by using part workbench (tool Close surface)

                                                    BOTTOM SUBSTRATE

 

                        ARMREST PART-1                                                                    ARMREST PART-2

 

 

                                     MAP POCKET PART-1                                                      MAP POCKET PART-2 

3. ATTACHMENT FEATURES:

>Between Bottom Substrate and Map Pocket:

 

• According to the Given master Sections, The attachment features for the Bottom Substrate are as follows.

According to the given Master Sections,

The attachment features for the Map Pocket are as follows:

• Attachment between Bottom Substrate and Map Pocket

 

>Between Map Pocket and Arm Rest:         

• The Master sections Between Arm Rest and Bottom Substrate are shown in the figure.
• According to the master sections, The attachment Features for Arm Rest created are Shown in the figure.
• Arm Rest Required Side Core Axis for Attachments.

 

 

 

• Attachments between Map Pocket and Arm Rest

 

FINAL ASSEMBLY WITH ATTACHMENT:

 

 

SOME OF THE ATTACHMENT FEATURES ARE ADDED WHEREVER THERE IS MISSING.

Master Sections of those attachment features as follows:

                               DOGHOUSE IN LOWER SUBSTRATE

 

 

                                                                    LOCK BETWEEN BOTH MAP POCKETS

 

 

                                                                     BETWEEN MAP POCKET AND LOWER SUBSTRATE

4.DRAFT ANALYSIS & TOOLING ANALYSIS:

In the injection molding process, plastic products are difficult to detach due to friction force between the cavity and products, thus, finished products might be deformed or damaged. Therefore, designers should add a draft angle to the geometric surface of products, which is parallel to the unloading direction, in order to help the products eject smoothly from the cavity. This study uses CAD software as the main architecture to develop the function of automatic draft angle recognition and construction. The study is divided into three stages. First, the geometric features of products are identified in the CAD model by induced algorithm, then the quilts to be added in the draft design are determined and classified. Finally, draft angles are created in different ways according to different surfaces

A. Bottom Substrate:

• Draft Analysis for Part shown in the figure
• No Side Core is required for the thickened Part
• The Draft angle for the attachment features is 0.5°

 

 

 B. Map Pocket:

• Draft Analysis for Part shown in the figure
• No Side Core is required for the thickened Part
• The Draft angle for the attachment features is 0.5°

Tooling Impossibility at a Portion:

1.

• The following portion is not cleared by the tooling direction.
• The part should be modified by the Class-A Designer.
• Hence, The Design feasibility is not possible. 

 

2.

• The following portion is parallel to the tooling axis.
• Hence, The Part should be modified by the Class-A Designer.

C. Arm Rest:

• The prats are having different tooling axis,
• Both the parts can meet tooling possibilities.

 

• The attachment features of the arm require different tooling axis.
• Hence, the Side core axis is derived for those attachment features.
• The draft report for the attachments is shown in the figure.
• The walls are with a draft angle of 0.5°

 

Tree Structure:

Assembly Tree Structure:

Part:1

  

 

Part 2:

  

 

Part 3:

 

Part 4:

 

 

Part 5:

 

Part 6:

 

CONCLUSION:

The Parts are created with the reference of master sections and Class-A surfaces. Tooling Axes are found for all the parts. Attachment features for all the parts are created. Draft analysis is done for all the parts. Modifications are done in some areas to meet draft analysis requirements.