Week 11 - Final project

Development of a door panel:

Aim: To design and assemble components of door panel from given A-surfaces.

The door panel is a plastic component attached to sheet metal part of door. It contains arm rest, Lower substrate, Map Pocket.

A-surfaces:

Door arm rest:

Map-Pocket-1:

Map-Pocket-2:

Lower substrate:

Creating B, C-surfaces:

Prior to creating B,C surfaces, each A-surface should be given a tooling direction. Draft analysis must be done slong that direction. Here Y-direction is considered for tooling. Tooling axis is created by placing a point anywhere on the surface and drawing along Y-direction.

Draft analysis of class-A surface:

Door arm rest:

Map-Pocket-1:

Map-Pocket-2:

Lower substrate:

B and C-surface creation:

Door arm rest:

Here the A-surface is offset to a distance of 2.5mm. The gaps in surface are resolved by extrapolating and trimming. The C-surfaces are created by blending between A,B on side and sweeping on other side.

The final surface is formed as shown below.

Map Pocket:

Class-B surface of both map pockets are created simply by offsetting A-surface to 2.5mm. C-surface in this case lies perpendicular to Tooling direction. So the surface is swept 90 degree with respect to tooling axis. Closed surfaces are formed by trimming B,C and joining it with A-surface.

Lower substrate:

Class-B is formed by offsetting to 2.5mm. C-surface is created by blending. Some areas swept 3 degrees if required.

The final closed surface is formed as shown below.

Attachment strategy:

The four components must be attached using flanges, heat stakes following the industrial design rules. For creating proper flanges, we need to refer master sections. From master sections it is clear that the thickness of flanges should be 2mm. The gap between each flange depends on the components being being attached. The gap lies in the range of 65-100mm. For flanges invovling armrest as a component, it is good to have the gap below 70mm. For combination of map pockets, higher values like 90-100mm can be taken. The heat stakes must be placed in appropriate locations. They are created following desing rules. Here heat stakes having OD=7mm, ID=5mm are taken. They are pad in Y- direction.

Attachment of lower substrate and arm rest:

Attachment of Two map pockets:

Attachment of map pocket with lower substrate:

Dog house:

The dog house is created using the following diagram and design rules.

Creating Dog house:

For a door panel three dog houses supporting pushpins are required. Here all of these are placed on lower substrate itself.

The clearence distance distance for each doghouse should be atleast three times the distance between front an back faces of dog house. Make sure these dog houses donot touch components surrounding lower substrate.

Lower substrate with dog houses and ribs:

Assembling Pushpins with Dog house:

Pushpins are added to assembly workbench. They are connected to doghouse on lower substrate using contact constraint.

Lower substrate with Pushpins attached:

Entire assembly of door panel:

Draft analysis of individual components:

Arm rest:

Lower substrate:

Map pocket-1:

Map pocket-2:

Final Door panel:

Front:

Back: