Week 11 - Final project

DEVELOPMENT OF A DOOR TRIM PANEL:

AIM:

• To design and development of vehicle interior door trim using catia v5 tool using give A class surface and adding thickness to it. Also to create a Ribs and locators as per the given master section

INTRODUCTION:

• This project explain in brief regarding the design life cycle followed in automotive industry by working on practical model car interior door trim which is a car interior trim part. In this report we have explain about the steps followed to create a solid body of the piller cover taking class A surface as input and creating a tooling axis and B surface with resect to the class A surface and creation of class C surface and also the draft analysis. The attachment features also designed and reported as per given master section considering all the design rules for the creation of ribs and doghouse.

Master Section:

• Master section are the guides for design requirements which decide the component packaging after technical (styling, concept or class -A) surfaces.

Following is the general workflow that is followed for the design and development interior and exterior automotive trims in OEMs.

• The styling and design teams at automotive OEM,s always walk an extra mile to make the best looking interior and exterior automotive trims. But when it comes to engineering for feasibility study, there are various constraints that are not well thought and analyzed due to time constraints. As a results, the best looking styling gets compromised in the production vehicle. Above shown workflow the initial activity of styling and class A surface modelling is done by the client and the rest of the activity is done by ASI with client representatives at every stages of development.
• To support OEMs overcome such challenge of delivering competitive and superlative quality automotive trims, we have come up with a methodical approach that focuses on the major selling points of the vehicle. The approach is explained through following 3 blogs:

Block-1: Class A surface engineering feasibility check & feedback.

Block-2: Matching concept design in detail.

Block-3: Master section, detailed design considerations, B surface modelling supplier feedback & drawing release.

Over view of design life cycle:

Research

• The Research design refers to the overall strategy that you choose to integrate the different components of the study in a coherent and logical way.thereby ensuring you will effectively address the research problem, it constitutes the blueprint for the collection, measurements and analysis of data.

Design requirements:

• The design requirements for a product are based on the wants and needs of the intended customer. These wants and needs must be identified by the company making the product, and they are often communicated by the target customer in nontechnical and sometimes vague terms.

Feasibility:

• In some cases, a feasibility study is carried out after which schedules, resource plans and estimates for the next phase are developed. He feasiblity study is an evaluation and analysis of the potential of a proposed projects to support the process of desired outcome. The feasibility study helps to narrow the scope of the project to identify the best scenario. A feasibility report is generated following which post feasibility review is performed.

Concept generation:

• A concept study is often a phase of project planning that includes producing ideas and taking into account the pros and cons of implementing those ideas. This stages of a project is done to minimize the likelihood of error, manage costs and evaluate the potential success of the intended project. In any event once an engineering issue or problem is defined, potential solutions must be identified. These solutions can be found by using ideation the mental process by which ideas are generated. It can be done normally by clay modelling.

Class A surface design:

• The preliminary design or high level design includes often bridges a gap between design conception and detailed design particularly in cases where the level of conceptualization achieved during ideation is not sufficient for full evaluation. So in this task, the overall system configuration is defined and schematics, diagrams and layouts of the projects may provide early project configuration. During detailed design and optimization the parameters of the part being created will change but the preliminary design focuses on creating the general framework to build the project on. This is also called as Class A surface Design. Styling or A class surface are terms used in plastic product design. That mean the surface of a component which is smooth (aesthetic) or visible side to human eye after the part is assembled. Class A surface of the interior door trim is as shown in picture below.

Design of interior Door trim:

• Interior Door Trim consists of 4 major components namely

1) Lower substrate

2) Upper substrate

3) Map pocket

4) Door Arm rest

• In this model we are designing only lower substrate, map pocket and door arm rest and attachment features like dog house and heat stakes and doing draft analysis for all the component.

Detailed design:

• This may consists of procurement of material as well. this phase further elaborates each aspect of the project ? product by complete description through solid modelling, drawing as well as specifications. Computer Aided design (CAD) programs have made detailed design phase more efficient. For example, a CAD program can provide optimization to reduce volume without hindering a parts quality. It can also calculate stress and displacement using the finite element method to determine stresses throughout the part. This involves the creation of tooling Axis, B class and C class surface creation with repect to the class A surface and also considering the draft angle. Design Engineer role is rominent in this stage.
• Design Engineers will study the input class A surface and master sections which is developed y the prelimnary design team and the procedure followed in creation of the Door arm rest are as below.

1) Designing of lower substrate, Arm rest and Map pocket

Map pocket - I

Class A surface

• In automotive design, a class A surface is any of a set of freeform surface of high efficiency and quality. Class A surfacing is done using computer-aided industrial design applications. Class A surface modelers are also called "digital sculptors" in the industry. Industrial designers develop their design styling through the A-Surface, the physical surface the end user can feel, touch, see etc.

Design check on Class A Surface:

• After reciving class a for the Map pocket - I check for the connectivity of the surface on it. If there is any disconnectivity, use join operation, multiple extract, multi section surface, boundary operation and disassemble.

Join operation:

• Go to join command to join the disconnectivity of the surfaces. Give merging distance =0.003mm.

• When there not connected, after reciving Class A surface, delete only the checking command of boundary operation and disassemble, When there are connected delete join operation, boundary operation and disassemble after the check. The check is over if any disconnectivity do not arise.

2. TOOLING AXIS:

• It is the dirction in which the mold open or core & cavity open. Part drafts are given along this axis.

Tooling operation:

• To deside the tooling axis, the component should be completely clearing the Tooling axis in the given specific direction. Analysis the components.
• First one visually check. We can check, which one is possible to Tooling Direction. We can check al x, y & z direcion. If you have hole, what it will happen, you haven separate side core for specific hole. In this draft analysis of fan cover Z – direction is the possible of Tooling direction.

• Publish it using INSERT – PUBLICATION – Select the Class A Surface & Tooling Axis.
• To make sure that easily visual to work on draft.

3. DRAFT ANALYSIS:

• Change view mode in material.

Customize view parameters.

• Choose the material in shading option.
• Use draft analysis option for class A surface and Tooling Axis.
• Go to INSERT – ANALYSIS – FEATURE DRAFT ANALYSIS.

Commands are to be used during Draft Analysis operation:

• The Draft Analysisdialog box is displayed. It gives information on the display (color scale), the draft direction and the direction values.
• The Draft Analysis.2dialog box showing the colour scale and identifying the maximum and minimum values for the analysis is displayed too.

Mode operation:

• The mode option lets you choose between a quick and a full analysis mode. These two modes are completely independent.
• The default mode is the quick mode. It simplifies the analysis in that it displays only three colour ranges.
• Double-click on the value in the colour scale to display the Value Edition dialog box.
• Enter a new value (negative values are allowed) to redefine the colour scale, or use the slider to position the distance value within the allowed range, and click OK.

Display Mode:

• Uncheck the Colour Scale checkbox to hide the Draft Analysis.2 dialog box, this dialog box only appears in edition mode.
• Activate the On the fly checkbox and move the pointer over the surface. This option enables you to perform a local analysis.
• Arrows are displayed under the pointer, identifying the normal to the surface at the pointer location (green arrow), the draft direction (red arrow), and the tangent (blue arrow). As you move the pointer over the surface, the display is dynamically updated. Furthermore, circlesare displayed indicating the plane tangent to the surface at this point.
• The On the fly analysis can only be performed on the elements of the current part.
• Click the No Highlight Representations button to set the display option of highlight effect sources as "on/off". When checked "On" the surfaces are selected but they will not be seen in the specification tree.
• Click the Light Effect button and the colours of the analysed elements react to the light source.
• Click the Inverse button to automatically reverse the draft direction.
• Click the Compass icon to define the new current draft direction.
• Click the Locked direction icon and select a direction (a line, a plane or planar face which normal is used), or use the compass manipulators, when available.

• Once you have finished analysing the surface, click OK in the Draft Analysis dialog box.

Mastersection Development:

• Master sections are the guides for design requirements which decide the component packaging after technical (styling, concept or class A) surfaces.

Following the master section we need to create the commponents.

B class surface creation:

• Once after getting the tooling axis we need to create the B surface which is parallel to the class A surface at the distance of the thickness of the component. It also includes the each and Every Edges, Fillets, Feature which is the in Class A surface. In the MAP POCKET-I the B surface are at the proportionate distance of 2.5mm from the class A surface.

C Class surface creation:

• Class C surface is swept along the boundry of the class A at an angle perpendiculer to the class A surface with respect to the Tooling Axis direction with a normal draft angle of 3 degree.

Combining Class A and C surface

• Once after creating the class B and class C, first join the class A and Class c surface together with a connexity of surface less than 0.003mm and The surfaces are merged. Merged surface are than to be trimmed with class B surface to get a closed surface.

Combining Class A, B and C to get a closed surfaces:

• The final trim of the Map pocket - I, it shows the closed surfaces.

• Once done with the generative sheet design, switch to part design and ADD the thickness to the closed surface in order to get the closed Volume body as a shown in the figure.

• For showing the below figure its the mastersection of the Map pocket - I with flanges.
• For creation of the master sections it involves Flanges.
• This is the final components of the Map pocket - I

Map pocket - II

Class A surface

• In automotive design, a class A surface is any of a set of freeform surface of high efficiency and quality. Class A surfacing is done using computer-aided industrial design applications. Class A surface modelers are also called "digital sculptors" in the industry. Industrial designers develop their design styling through the A-Surface, the physical surface the end user can feel, touch, see etc.

Design check on Class A Surface:

• After reciving class a for the Map pocket - II check for the connectivity of the surface on it. If there is any disconnectivity, use join operation, multiple extract, multi section surface, boundary operation and disassemble.

Join operation:

• Go to join command to join the disconnectivity of the surfaces. Give merging distance =0.003mm.

• When there not connected, after reciving Class A surface, delete only the checking command of boundary operation and disassemble, When there are connected delete join operation, boundary operation and disassemble after the check. The check is over if any disconnectivity do not arise.

2. TOOLING AXIS:

• It is the dirction in which the mold open or core & cavity open. Part drafts are given along this axis.

Tooling operation:

• To deside the tooling axis, the component should be completely clearing the Tooling axis in the given specific direction. Analysis the components, the components has two walls.
• First one visually check. We can check, which one is possible to Tooling Direction. We can check al x, y & z direcion. If you have hole, what it will happen, you haven separate side core for specific hole. In this draft analysis of fan cover Z – direction is the possible of Tooling direction.

• Publish it using INSERT – PUBLICATION – Select the Class A Surface & Tooling Axis.
• To make sure that easily visual to work on draft.

3. DRAFT ANALYSIS:

• Change view mode in material.

Customize view parameters.

• Choose the material in shading option.
• Use draft analysis option for class A surface and Tooling Axis.
• Go to INSERT – ANALYSIS – FEATURE DRAFT ANALYSIS.

Commands are to be used during Draft Analysis operation:

• The Draft Analysisdialog box is displayed. It gives information on the display (color scale), the draft direction and the direction values.
• The Draft Analysis.2dialog box showing the colour scale and identifying the maximum and minimum values for the analysis is displayed too.

Mode operation:

• The mode option lets you choose between a quick and a full analysis mode. These two modes are completely independent.
• The default mode is the quick mode. It simplifies the analysis in that it displays only three colour ranges.
• Double-click on the value in the colour scale to display the Value Edition dialog box.
• Enter a new value (negative values are allowed) to redefine the colour scale, or use the slider to position the distance value within the allowed range, and click OK.

Display Mode:

• Uncheck the Colour Scale checkbox to hide the Draft Analysis.2 dialog box, this dialog box only appears in edition mode.
• Activate the On the fly checkbox and move the pointer over the surface. This option enables you to perform a local analysis.
• Arrows are displayed under the pointer, identifying the normal to the surface at the pointer location (green arrow), the draft direction (red arrow), and the tangent (blue arrow). As you move the pointer over the surface, the display is dynamically updated. Furthermore, circlesare displayed indicating the plane tangent to the surface at this point.
• The On the fly analysis can only be performed on the elements of the current part.
• Click the No Highlight Representations button to set the display option of highlight effect sources as "on/off". When checked "On" the surfaces are selected but they will not be seen in the specification tree.
• Click the Light Effect button and the colours of the analysed elements react to the light source.
• Click the Inverse button to automatically reverse the draft direction.
• Click the Compass icon to define the new current draft direction.
• Click the Locked direction icon and select a direction (a line, a plane or planar face which normal is used), or use the compass manipulators, when available.

• Once you have finished analysing the surface, click OK in the Draft Analysis dialog box.

Mastersection Development:

• Master sections are the guides for design requirements which decide the component packaging after technical (styling, concept or class A) surfaces.

Following the master section we need to create the commponents.

B class surface creation:

• Once after getting the tooling axis we need to create the B surface which is parallel to the class A surface at the distance of the thickness of the component. It also includes the each and Every Edges, Fillets, Feature which is the in Class A surface. In the MAP POCKET-II the B surface are at the proportionate distance of 2.5mm from the class A surface.

C Class surface creation:

• Class C surface is swept along the boundry of the class A at an angle perpendiculer to the class A surface with respect to the Tooling Axis direction with a normal draft angle of 3 degree.

Combining Class A and C surface

• Once after creating the class B and class C, first join the class A and Class c surface together with a connexity of surface less than 0.003mm and The surfaces are merged. Merged surface are than to be trimmed with class B surface to get a closed surface.

Combining Class A, B and C to get a closed surfaces:

• The final trim of the Map pocket - II, it shows the closed surfaces.

• Once done with the generative sheet design, switch to part design and ADD the thickness to the closed surface in order to get the closed Volume body as a shown in the figure.

• For showing the below figure its the mastersection of the Map pocket - II with flanges.
• For creation of the master sections it involves Flanges.
• This is the final components of the Map pocket - II

Door Trim:

Class A surface

• In automotive design, a class A surface is any of a set of freeform surface of high efficiency and quality. Class A surfacing is done using computer-aided industrial design applications. Class A surface modelers are also called "digital sculptors" in the industry. Industrial designers develop their design styling through the A-Surface, the physical surface the end user can feel, touch, see etc.

Design check on Class A Surface:

• After reciving class a for the Door Trim check for the connectivity of the surface on it. If there is any disconnectivity, use join operation, multiple extract, multi section surface, boundary operation and disassemble.

Join operation:

• Go to join command to join the disconnectivity of the surfaces. Give merging distance =0.001mm.
• The following class A surface are use to improve the Class A Surface.

• When there not connected, after reciving Class A surface, delete only the checking command of boundary operation and disassemble, When there are connected delete join operation, boundary operation and disassemble after the check. The check is over if any disconnectivity do not arise.

2. TOOLING AXIS:

• It is the dirction in which the mold open or core & cavity open. Part drafts are given along this axis.

Tooling operation:

• To deside the tooling axis, the component should be completely clearing the Tooling axis in the given specific direction. Analysis the components, the components has two walls.
• First one visually check. We can check, which one is possible to Tooling Direction. We can check al x, y & z direcion. If you have hole, what it will happen, you haven separate side core for specific hole. In this draft analysis of fan cover Z – direction is the possible of Tooling direction.
• Both of the tooling axis is to take at in the heat stake and normal tooling axis.

• Publish it using INSERT – PUBLICATION – Select the Class A Surface & Tooling Axis.
• To make sure that easily visual to work on draft.

3. DRAFT ANALYSIS:

• Change view mode in material.

Customize view parameters.

• Choose the material in shading option.
• Use draft analysis option for class A surface and Tooling Axis.
• Go to INSERT – ANALYSIS – FEATURE DRAFT ANALYSIS.

Commands are to be used during Draft Analysis operation:

• The Draft Analysisdialog box is displayed. It gives information on the display (color scale), the draft direction and the direction values.
• The Draft Analysis.2dialog box showing the colour scale and identifying the maximum and minimum values for the analysis is displayed too.

Mode operation:

• The mode option lets you choose between a quick and a full analysis mode. These two modes are completely independent.
• The default mode is the quick mode. It simplifies the analysis in that it displays only three colour ranges.
• Double-click on the value in the colour scale to display the Value Edition dialog box.
• Enter a new value (negative values are allowed) to redefine the colour scale, or use the slider to position the distance value within the allowed range, and click OK.

Display Mode:

• Uncheck the Colour Scale checkbox to hide the Draft Analysis.2 dialog box, this dialog box only appears in edition mode.
• Activate the On the fly checkbox and move the pointer over the surface. This option enables you to perform a local analysis.
• Arrows are displayed under the pointer, identifying the normal to the surface at the pointer location (green arrow), the draft direction (red arrow), and the tangent (blue arrow). As you move the pointer over the surface, the display is dynamically updated. Furthermore, circlesare displayed indicating the plane tangent to the surface at this point.
• The On the fly analysis can only be performed on the elements of the current part.
• Click the No Highlight Representations button to set the display option of highlight effect sources as "on/off". When checked "On" the surfaces are selected but they will not be seen in the specification tree.
• Click the Light Effect button and the colours of the analysed elements react to the light source.
• Click the Inverse button to automatically reverse the draft direction.
• Click the Compass icon to define the new current draft direction.
• Click the Locked direction icon and select a direction (a line, a plane or planar face which normal is used), or use the compass manipulators, when available.

• Once you have finished analysing the surface, click OK in the Draft Analysis dialog box.

Mastersection Development:

• Master sections are the guides for design requirements which decide the component packaging after technical (styling, concept or class A) surfaces.

Following the master section we need to create the commponents.

B class surface creation:

• Once after getting the tooling axis we need to create the B surface which is parallel to the class A surface at the distance of the thickness of the component. It also includes the each and Every Edges, Fillets, Feature which is the in Class A surface. In the DOOR TRIM the B surface are at the proportionate distance of 2.5mm from the class A surface.

C Class surface creation:

• Class C surface is swept along the boundry of the class A at an angle perpendiculer to the class A surface with respect to the Tooling Axis direction with a normal draft angle of 3 degree.

Combining Class A and C surface

• Once after creating the class B and class C, first join the class A and Class c surface together with a connexity of surface less than 0.003mm and The surfaces are merged. Merged surface are than to be trimmed with class B surface to get a closed surface.

Combining Class A, B and C to get a closed surfaces:

The final trim of the Door Trim, it shows the closed surfaces.

Once done with the generative sheet design, switch to part design and ADD the thickness to the closed surface in order to get the closed Volume body as a shown in the figure.

For showing the below figure its the mastersection of the Door trim with flanges.

For creation of the master sections it involves Flanges.

This is the final components of the Door Trim

LOWER SUBSTACK:

Class A surface

• In automotive design, a class A surface is any of a set of freeform surface of high efficiency and quality. Class A surfacing is done using computer-aided industrial design applications. Class A surface modelers are also called "digital sculptors" in the industry. Industrial designers develop their design styling through the A-Surface, the physical surface the end user can feel, touch, see etc.

Design check on Class A Surface:

• After reciving class a for the LOWER SUBSTACK check for the connectivity of the surface on it. If there is any disconnectivity, use join operation, multiple extract, multi section surface, boundary operation and disassemble.

Join operation:

• Go to join command to join the disconnectivity of the surfaces. Give merging distance =0.001mm.
• The following class A surface are use to improve the Class A Surface.

• When there not connected, after reciving Class A surface, delete only the checking command of boundary operation and disassemble, When there are connected delete join operation, boundary operation and disassemble after the check. The check is over if any disconnectivity do not arise.

2. TOOLING AXIS:

• It is the dirction in which the mold open or core & cavity open. Part drafts are given along this axis.

Tooling operation:

• To deside the tooling axis, the component should be completely clearing the Tooling axis in the given specific direction. Analysis the components, the components has two walls.
• First one visually check. We can check, which one is possible to Tooling Direction. We can check al x, y & z direcion. If you have hole, what it will happen, you haven separate side core for specific hole. In this draft analysis of fan cover Z – direction is the possible of Tooling direction.
• Both of the tooling axis is to take at in the heat stake and normal tooling axis.

• Publish it using INSERT – PUBLICATION – Select the Class A Surface & Tooling Axis.
• To make sure that easily visual to work on draft.

3. DRAFT ANALYSIS:

• Change view mode in material.

Customize view parameters.

• Choose the material in shading option.
• Use draft analysis option for class A surface and Tooling Axis.
• Go to INSERT – ANALYSIS – FEATURE DRAFT ANALYSIS.

Commands are to be used during Draft Analysis operation:

• The Draft Analysisdialog box is displayed. It gives information on the display (color scale), the draft direction and the direction values.
• The Draft Analysis.2dialog box showing the colour scale and identifying the maximum and minimum values for the analysis is displayed too.

Mode operation:

• The mode option lets you choose between a quick and a full analysis mode. These two modes are completely independent.
• The default mode is the quick mode. It simplifies the analysis in that it displays only three colour ranges.
• Double-click on the value in the colour scale to display the Value Edition dialog box.
• Enter a new value (negative values are allowed) to redefine the colour scale, or use the slider to position the distance value within the allowed range, and click OK.

Display Mode:

• Uncheck the Colour Scale checkbox to hide the Draft Analysis.2 dialog box, this dialog box only appears in edition mode.
• Activate the On the fly checkbox and move the pointer over the surface. This option enables you to perform a local analysis.
• Arrows are displayed under the pointer, identifying the normal to the surface at the pointer location (green arrow), the draft direction (red arrow), and the tangent (blue arrow). As you move the pointer over the surface, the display is dynamically updated. Furthermore, circlesare displayed indicating the plane tangent to the surface at this point.
• The On the fly analysis can only be performed on the elements of the current part.
• Click the No Highlight Representations button to set the display option of highlight effect sources as "on/off". When checked "On" the surfaces are selected but they will not be seen in the specification tree.
• Click the Light Effect button and the colours of the analysed elements react to the light source.
• Click the Inverse button to automatically reverse the draft direction.
• Click the Compass icon to define the new current draft direction.
• Click the Locked direction icon and select a direction (a line, a plane or planar face which normal is used), or use the compass manipulators, when available.

• Once you have finished analysing the surface, click OK in the Draft Analysis dialog box.

Mastersection Development:

• Master sections are the guides for design requirements which decide the component packaging after technical (styling, concept or class A) surfaces.

Following the master section we need to create the commponents.

B class surface creation:

• Once after getting the tooling axis we need to create the B surface which is parallel to the class A surface at the distance of the thickness of the component. It also includes the each and Every Edges, Fillets, Feature which is the in Class A surface. In the DOOR TRIM the B surface are at the proportionate distance of 2.5mm from the class A surface.

C Class surface creation:

• Class C surface is swept along the boundry of the class A at an angle perpendiculer to the class A surface with respect to the Tooling Axis direction with a normal draft angle of 3 degree.

Combining Class A and C surface

• Once after creating the class B and class C, first join the class A and Class c surface together with a connexity of surface less than 0.003mm and The surfaces are merged. Merged surface are than to be trimmed with class B surface to get a closed surface.

Combining Class A, B and C to get a closed surfaces:

The final trim of the Door Trim, it shows the closed surfaces.

Once done with the generative sheet design, switch to part design and ADD the thickness to the closed surface in order to get the closed Volume body as a shown in the figure.

Creation of Ribs and Dog house:

• Ribs provide a economical stiffness and strength in molded parts without increasing overall wall thickness. They also facilitate,

1. Locating and arresting the components of an assembly.

2. providing allignment in mating parts.

3. Acting as stops and guides for the mechanisms.

• Proper rib design involves 5 main issues:

1. Thickness

2. Height

3. Location

4. quantity

5. Manufacturability

• Considering above displayed standrds, we have designed the Dog house and Ribs as per Mastersection provided as shown in the figure:

DOG HOUSE

• For showing the below figure its the mastersection of the LOWER SUBSTACK with flanges.
• For creation of the master sections it involves Flanges.
• This is the final components of the LOWER SUBSTACK

DEVELOPMENT OF A DOOR PANEL:

STREE STRUCTURE:

Conclusion:

• Thus the interior trim of the car interior door trim is designed using the given A class Surface as the input and B and C class surfaces are created with respect to the A class surface. By using the given Master section attachment features i.e. Ribs and dog house, flanges and pushclips created considering all the design rules for creation of ribs and doghouse. Also carried out the draft analysis to check weather the component is easily manufacturable or not with given draft of 3 degrees for the surfaces and 0.5 degrees for the attachment features. with all theses dates and report we can conclude that the draft analysis is very important to design any plastic component because when we making a part that will be molded, the analysis will verify that all surfaces are favorable for being pulled from a cavity. It may also highlight or give insight to "trouble" areas.