Week 11 - Final project
AIM:
To create a solid body of Side Door plastic trim including the engineering features using catia v5 tool using given A class surface and master section and adding thickness.
INTRODUCTION :
Side Door Plastic Trim
An interior component attached to the inner side of the door. This product does more than merely improve the appearance of the vehicle interior. Rather, it is a vital module component that creates a more comfortable interior by providing a variety of accoutrements and functions.
The Stages of Design Life Cycle are
Concept Sketches:
Concept sketches are rough idea of free hand sketch obtained through styling team and will be used to prepare the Model. It is usually done through pen and paper and through the painting software. This is will be used to generate the concept for preparing the model by incorporating various styles and information obtained through the stakeholders
Class A Creation:
After finalizing the concept the sketches are usually worked in software’s such as Autodesk Alias to create Class A Surface
Clay Modeling :
The Class A Surface is concurrently worked by clay modelers to brainstorm and benchmark the styling of the product and later the Concept is validated by bringing up a rough clay model and then it is passed on to the Design team for the preparation of New Product Design (NPD) CAD.
NPD CAD :
This where the development of surfaces to parts in CAD kick off and Design engineers involvement is vital in this stage.
The Designers will work on the Input Class A surfaces which are validated from the Feasibility team
The procedure followed in creation of the plastic New Product Design are
- Tooling Axis
- B Surface Creation
- C Surface Creation
- Closed Body Creation
- Draft Analysis
PROCEDURE:
1) Input Given :
Design of Interior Door trim:
Interior Door trim consists of four components
1)Lower Substrate
2)Upper Substrate
3)Map Pocket
4)Door Arm Rest
2) A Class Surface
In automotive design, a class A surface is any of a set of freeform surfaces of high efficiency and quality. Although, strictly, it is nothing more than saying the surfaces have curvature and tangency alignment – to ideal aesthetical reflection quality, many people interpret class A surfaces to have G2 (or even G3) curvature continuity to one another. Class A surfacing is done using computer-aided industrial design applications. Class A surface modellers 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.
Door Arm Rest
Map Pocket
Lower Substrate
3)Tooling Axis
Tooling axis is nothing but the direction in which the core and cavity opens and closes. Design engineer works is to analyse the Class A surface and find out the best possible tooling direction keeping in mind all the draft angle is with respect to the tooling axis so that the component can be easily ejected from the moulds.
Door Arm Rest
Map Pocket
Lower Substrate
4) Draft Analysis
The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.
Draft angles are very important in thermoforming product design. If the product is formed onto a female or negative mold, it shrinks away from the mold sidewalls. As a result, true female or negative products can be thermoformed with vertical walls having zero draft angles. Parts Cannot be ejected from the tool if it is at 90 degree surface.for the reason,A small Draft angle is to be provide for each and every surface s of the Component in order to easy removal of component from the moulds without any defects.Draft is the angle in which the part is tapered to aloow it to release.Most of the part require minimum 1/2 degree to 1 degree however 3 degrees are widely accepeted in plastic component design.Draft Analysis is the technique used to analise weather our designed product are manufacturable with required conditions or not.
Door Arm Rest
With main tooling axis
With slider axis
Map pocket
Lower Substrate
Some surfaces which are not clearing the draft analysis needsimprovement in the A class surface.
5) B Class Surface Creation
Represent internal and/or functional surfaces. This cluster exemplary includes derived surfaces created by offset operations from class A surfaces to define the thickness of material. In this file it is important to link class B surfaces geometrically to enable an adaptation to class A surfaces automatically in case of styling change.
After creating the tooling axis, B surface is to be created which is nothing but the surface parallel to the A surface. B surface contains all the fillets and the edges which the A surface contains.
Door Arm Rest
Map pocket
Lower Substrate
6) C Class Surface Creation
Class C Surface is swept along the boundry of the Class A at an angle perpendicular to the CLASS A surface with respect to the tooling axis direction with a draft angle of 3 degree.
Door Arm Rest
Map pocket
Lower Substrate
7) Joining CLASS A, B and C Surfaces to get a Closed Surfaces
After finishing all the 3 surfaces, join the class A and class C surface together using the Join command. Now, the joined surfaces are then trimmed with class B surface to form a closed surface.
Door Arm Rest
Map pocket
Lower Substrate
Now, switch to Part design and Add the thickness to the closed surface in order to get the closed solid body as shown in the figure below.
Door Arm Rest
Map pocket
Lower Substrate
8) Creation of Flanges, Ribs,Dog house and Heat Stakes :
Heat Stakes:
Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic. The process is to deform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part in order to fix the other.
Dog House :
Create the dog house as per the design rules and give the required draft angle.
Door Arm Rest
Map pocket
Lower Substrate
9) Draft Analysis of the Final Component
Door Arm Rest
With main tooling axis
With slider axis
Map pocket
- Some surfaces which are not clearing the draft analysis needs improvement in the A class surface.
Lower Substrate
For B side features
Final Model Image:
Result :
- Class A, B and C surface was created as per the automotive standards using catia v5software.
- Draft analysis was performed for the built model and it could be seen that the draft was under permissible limit for the manufacturing of the component.
- B side features were created for the component as per the design rules.