Week 11 - Final project

Door Trim Panel:-

In this design we will work on 3 different components:

1) Map Pocket (Upper and lower part)

2) Door Arm Rest (Upper and lower part)

3) Lower Substrate

Report:-

1) Map Pocket Upper Part: -

Extract the component surface from the given plastic component. This extracted surface will be a class A surface for the armrest upper part and join it with an extended flange.

Creation of Tooling Axis: Tooling axis should be designed such that the class A surface should appear green that means it should be clear in draft analysis.

Draft Analysis:

Creation of B surface: The thickness of this surface should be 2.5mm, therefore we need to offset this class A surface to 2.5mm. This will be the B surface. Sometimes while offsetting the class A surface there may be some areas that may not get offset. So in that case, we need to create that element manually.

Creation of C surface: For Creation of C surface, we need to sweep in axis direction at 3 degree and join it with class A surface. Now trim it with B surface. Make sure the obtained body is fully closed. Now go to Part Design and use the “closed body” command to make the body solid.

Trim that class C with Class A surface make it close body.

Map Pocket Lower Part:

Creation of Class A surface: Extract the surface from the given component.

Creation of Tooling Axis: Take a point on the surface of the class A surface and draw the line through the point in the vertical direction of the surface and make sure that the body is being cleared in the draft analysis.

Draft analysis:

Note- Some elements for this class A surface does not cleared in draft analysis. This issue caused because of isuue in Class S surface.

To the creation of B surface offset the class A surface to about 2.5mm and extrapolate the class B surface for trim with class A surface.

By using Sweeps and Multi-Section surface we can create C surface and then join it A surface. And then trim it with Class B surface and make a Close solid body.

2) Arm Rest Upper Part:

Class A Surface:

Draft Analysis-

Creation of Class B surface:-

Creation Of Class C Surface:-

Now trim it with class B Surface and make it solid body:-

Arm Rest Lower Part:

Class A Surface:

Draft Analysis:-

B surface-

C Surface-

Now trim it with Class B surface and make a Solid body.

3) Lower Substrate:

Class A Surface:

Creation of Class B Surface-

Create Class C Surface by using Sweeps and Multi-Section and trim it with Class B surface.

Accessories:

Dog House: Dog houses are needed to give extra strength to the components and to avoid sink marks and increase the height for push pins. Push pin is Already given as input, so according to Push pin, we calculate the diamentions for Dog House.

The minimum width of the dog house should be 12mm.

Push Pin-

Dog House-

Heat Stakes: Heat stakes are used to join one or more plastic components. Give the draft of 3 degrees to the heat stakes in both outer and inner sides.

Door Trim Panel Solid Design: