Week 11 - Final project

AIM:-

To create the Door trim considering the inputs given to me following the design rules and OEM standards.

ABSTRACT:-

The project deals with the explanation of steps and procedures followed while developing the Door Trim Panel of a car using CATIA V5. Using the class A surface I was able to create the tooling axis, class B surface, class C surface, and after forming the solid body from that I was able to create the flanges and the B side features such as Dog house, push pinsHeat stakes, etc. And finally, the draft analysis is done on the components to check the manufacturability of the components.

INTRODUCTION:-

The door panel will usually match the rest of the vehicle's interior Door panels were formerly made of cardboard with an upholstered interior finish of vinyl, leather, cloth, carpet, or other materials for the decorative trim. Modern cars typically have door cards made of plastic, most often using injection molding, as well as incorporating other decorative materials.

The design should incorporate both the necessary service amount and the fanctional unit Such as "it is strong and "it looks and feels good") that a given car door panel "would service a car body's life span of 200,000 kilometers (124.274 mi)." The door panel typically incorporates other parts that contribute to the apperance, functionality, and ergonomics of the vehicle. These include arm rest, switches, or other controls for windows and the locking mechanism, convenience lights, Map pockets, lower substrate, storage compartments, and other features. An image of the door trim panel is shown below:

The steps that i followed for this project is mentioned below:-

1) Extracting the class A surtace fromilie input.

2) Draft Analysis of class A.

3) Creation of Class B and Class C surface from Class A .

4) Created the soid body and formed the draft analysis on the sold body.

5) created the flanges.

6) Created the Engineering features.

7) Draft analysis of the component with Engineeing features.

PROCEDURE:-

Here the input which is giveh to me is below:-

In the above figure you can see that the surfaces along with the master section are given to me.

MASTER SECTION:-

Master section are the guides for a design that shapes the component after technical styling of class A surface. The master section is parameterized model of the vehicle body that outlines the guidelines for the NPD team.

so here i have to create three parts that are mentioned below:

1) Lower substrate.

2) Map pocket 1.

3) Map pocket 2.

4) Door Arm rest.

Then i have to create the attachment features that are required for the assembly of the parts. First i have started by creating the lower substrate. For this I have extracted the class A surface of the lower substrate from the input that is given. 

Class A of the Lower substrate as shown in below:

I have split the extra portion from the class A surface by creating a line and splitting using the split feature in generative shape design so the final A surface as shown below:

CLASS B SURFACE:-

It is a surface that gives thickness from a class A surface. All the supporting features of the component will be formed on the B surface only. so we can say that Class B is an engineering surface and Class A is an aesthetic surface. For creating the class B surface I have offset the Class A surface to 25 mm which is the thickness of the part according to the master section that is given as the input. The offset is shown below:

CLASS C SURFACE:-

Class C surface is defined as the surface which connects the CLASS A and CLASS B surface along the tooling direction. The tooling direction here will be my tooling axis. For creating Class C. l have extracted the boundaries of the class A surface and take a sweep operation with taking referance surface with an angle 90 degree. Also, I have used the smooth curve feature to smoothen the swept surfaces. The sweep parameters are shown below:

Now join surface A and surface C and then we get a final product as shown below:

Final product:

Then i have performed draft analysis on that solid part.

For Arm rest, Map pocket 1, Map pocket 2:-

We take a same procedure as per we done for making lower substrate. Make sure the all parts of the door trim pannel is to be solid or they are closed in nature.

Arm rest:

Map pocket 1:

Map pocket 2:

All the different part to be combine here:

Flange:-

Flanges are the elements that are needed to join different components together So here i have to make flanges. on the door arm rest and the map pocket. Following the master section, given as the input basically the measurements and location of the flange. I have created the flanges. First i have created the flange on the outer map pocket. For creating the flanges i have taken extraction of the curve and made a point on that curve then created one plane on that point followed by creating a sketch on that plane taking the point created as the origin. Then i have provided the draft and fillets to the flange. The fillets value can be taken from the master section if given or you can provide a minimum fillet of 1 mm coming to the draft value here for the outer map pocket i have provided 3 degrees but if the flange size is less than you can provide a minimum draft of 0.5 degrees.The sketch is shown below:

Then i have copied the flange body and paste it on the main part body using the as result with a link option in paste special. After pasting i have translated the flange using the point-to-point translation feature keeping in mind the spacingrule that is the gap between two flanges should be 10 - 50 mm. Then after the translation i have used the union trim operation to make one single body. The outer map pocket with flange is shown below:


The same thing i did for the other parts also that is extracted the curves in which the range is required then i made a point and plane then sketched on it to create flanges later provided drafts and fillets. The flanges of the inner map pocket are shown below for this part have given 0.5 degrees draft to the flanges.

After creating the flanges i have created the dog house.

DOG HOUSE:-

Dog house is an engineering feature used in the plastic trim design. Dog houses are used as supporting features. Sometimes other engineering features like snaps, locators, etc. are mounted on them to increase their strength. Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from the mold cavity. Dog house and other engineering components are built on B-surface.

Here we create a dog house sketch

Then i have swept the above sketch along the tooling axis of the lower substrate with the draft 1.5 degree.

Then i have close the surface on the top, after closing the surface i applied thick surface tool to give the thickness.

now for the dog house also we will require an additional axis which is called a lifter as that would clear the inside portion of the dog house because it wont be clear using the main tooling axis. so for creating that lifter tooling axis have created one point on the back surface of the dog house and from that point created one line and that line is my lifter axis. red line indicate lifter axis. The lifter axis shown below:

Now according to this tooling axis, I have drafted the inner portion of the dog house. the draft value I have given 0.5 degree. Actually, i have given the draft before giving the inner fillets and that is the correct method to do it later you can give fillets. The draft is shown below:

Dog house wall thickness and sink saver:

For this purpose, i have just offset base of lower substrate to the height of 5 to 10mm, after that i extracted in inside portion of the dog house. Then i have extrapolate the inside portion that i extracted and trimmed with the base surface. i offset 1mm to making C surface then trim perform. 
After trimming i have the trim 1 mm considering of the component is 2mm so 40% of 2mm. After offsetting it to 1mm i have split the offset surface with split the offset surface. Now we can provide the fillets so the dog house is completed.

Next, i have created the push pins. another there are basically attached to the dog house.

PUSH PIN:-

Push pins are used for joining one component the push pins have taken the following reference basically the measurements. Then i have used the copy and paste option and translated the dog house along with a push pin to different locations on the lower substrate in which i want the dog house so basically i have created points on the lower substrate and used the point-to-point translation. After doing the transtation i have just added all the dog houses to the lower substrate. The result is as shown below:

Then at last i have created the Heat stakes but let's see what is Heat staking.

HEAT STAKING:-

Heat stakıng also known as thermoplastic staking is the process of joining two dissimilar materials together. In heat staking, we use local heating and cooling to raise the temperature of plastic components and allow plastic reforming to be carried out. This reforming can be used in a wide variety of applications.

Applications range from staking plastic bosses for assembly of car door panels to joining PCBS to plastic housings. Benefits of this technique include, no vibration damage, no particulates, the ability to stake metalized coated applications, and the capability to stake in difficult to access or restricted areas.

The progressive melting of plastic under continuous pressure forms the bead. When staking the right combination of heat and pressure for the application is critical.

The advantages of Heat staking are as follows:

1) simplification of the machinery.

2) Reduced cost of machinery.

3) Multiple fastening points.

4) Allows higher density of welds compared to hot air cold form or ultrasonic welding Before creating the heat stakes. I have created the holes on all the flanges that i created earlier. For the hole, i have created one point on the upper face of the flange and created a sketch on it. The sketch Is shown below: 

 

DRAFT ANALYSIS:-

Draft analysis is a technique to analyze whether the component created is manufacturable or not based on the draft conditions applied. So here i will provide the direction in which the compenent should be ejected to get the easy removal. My direction will be the tooling axis that i have created. The minimum draft value for the Automotive plastic component is 8 degrees and those for the texture faces 7 degrees of the draft is suitable. The draft is provided to the component for easy removal from the mold in the case of the plastic components. So here i will change the customize view parameters and will select the material mode.

The color scale shown above denotes the following:

The Green color denotes that the draft provided is above 0.49 degrees.

The Blue color denotes that the draft provided is between 0 and 0.49degrees.

The Red color denotes that the draft provided is negative.

After performing the draft analysis i have made sure that the proper draft is provided on the component and now i can create the further surfaces which are class B and Class C surfaces.

ARM REST:

LOWER SUBSTRATE:

MAP POCKET 1:

MAP POCKET 2:

CONCLUSION:

We understand how to make door trim panel by using master section. As we make a flanges, heat stakes, dog house by using engineering features also assemble push pin over dog house and draft analysis on every parts of the door trim panel.