Week 11 - Final project

DESIGN AND DEVELOPMENT OF DOOR TRIM PANEL

AIM:

• To design and development of vehicle interior door drim using Catia v5 with the given class A surface along with the master section.Also create the side attachment features ass per design rules.

OBJECTIVE:

• To create the thickned part using master section for refference.
• To create the mounting features are per design guidelines in the industry and with the master section.
• To perform draft analysis & tooling analysis.

INTRODUCTION:

• The door panel is the interface between the interior of the car and the inner workings of the door.Generally the door pane is divided into two parts of easy designing like arm rest,map pocket,lower substrate,bottle holder.
• These requires one of the toughest requirement among the interior parts of the car.This should be designed to with stand the load while being lessthan 2mm in the thickness and also protect the occupants during collisions.
• Door currently have an inner full width panel consisting of electric windows.These panels typically consists of a covered with either textiles or plastics.

The stages of design life cycle are

Concept Sketches:

• Concept sketches are rough ideas 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 painting software.
• This will be used to generate the concept for preparing the model by incorporating various styles and information obtained through stakeholders.

Clay modelling:

The class A surface is concurrently worked by the clay modelers to brainstrom 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:

1. This is where the development of surfaces to parts in CAD kick off and design engineers involvement is vital in this stage.
2. The designers will work on the input class A surfaces which are validated from the feasibility team.
3. The procedure followed in creation of the plastic new product designs are

• Tooling axis
• B surface creation
• C surface creation
• Closed body creation
• Draft analysis

PROCEDURE OF PART CREATION:

1. Input Given:

Design of interior door trim:

Lower Substrate

Upper Substrate

Map pocket

Door Arm Rest

2. Class A surface:

• In automotive design,a class A surface in any of a set of freedom surfaces of high efficiency and quality.Although,strictly its nothing morethan saying the surfaces have curvature and tangency alignment-to ideal asethetical reflection quality,many people interpret classA surfaces to have G2 or even G3 curvature continuity to one another.Class A surfacing is done using computer aided industial design applications.
• Class A surfaces modellers are also called "digital sculptors" in the industry.Industrial designers develope their design styling through A-surface,the physical surface the end used user can feel,see touch etc.

3.Tooling Axis:

• Tooling axis is nothing but the direction in which the core and cavity opens and closes.Design engineer works on it to analyse the classA surface and finds 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.

4.Draft analysis:

• The draft analysis command enables you to detect if the part you drafted willbe easily removed.This type of analysis is basedd on color ranges identifying zones on the analysed element where the deviation from the draft direction at any point,corresponds to specified values.
• Draft angles are very important in thermoforming product designs,if the product is formed onto a female or negative moulds,it shrinks away from the mould side wals.
• 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 that reason,a small draft angle is to be provided for each and every surface of the component in order to easy removal of the component from the moulds without any defects.
• Most of the part require minimum 0.5 degree to 1 degree,however 3 degree is widely accepted in plastic component design.Draft analysis is the technique used to analyse weather our designed product are manufacturable with required conditions are not.
• Some surfaces which are not clearing the draft analysis needs improvement in class A surface.

5.Class B surface creation:

• Class B surface includes derived surfaces created by offset operations from class A surfaces to define the thickness of the material.In this file it is important to link Class B surfaces geometrically to enables 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 surfaces parallel to the A surface. B surface contains all the fillets and the edges which the A surfaces contains.

6.Class C surface creation:

• Class C surface is swept along the boundary 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.

7.Joining Class A,B and C surface to get a closed surface:

• After finishing all the 3 surfaces,join the class A and Class C surface together using join command.Now,the joined surfaces are then trimmed with the Class B surface to form a closed surface.
• 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 fig below.

8.Designing B Side Features:

DOG HOUSE:

• Primary function of the dog house is to avoid sink marks.But it also helps in other things like if the mating part is to be at a greater distance then we cannot make the height of the screw boss of that greater height,thus we make dog house and mount screw boss on it.Hence it helps in solving the problem of screw boss and also it helps to have to perpendicular screw boss.
• There are certain guidelines to be followed while creating the dog house which followed in the project properly.Push clips are mounted on this dog house.But as push clip are manufactured else where and is not in our zone of concern so we have ignored the rules while making the push clips.

HEAT STAKES:

• Heat staking is a pulsed-heat process to join two or more parts out of which one atleast is made of plastic.
• The process to deform the plastic material using heat and forces at a set of process time.The bond is made bt partially deforming the plastic part in order to fix the other.

LOCATORS:

• In order to completely specify the position in space of a three-dimensional object .We refer to six coordinates with total 12 degrees of freedom.

1. Translational position along the X-axis
2. Translational position along the Y-axis
3. Translational position along the Z-axis
4. Rotational position about the X-axis
5. Rotational position about the Y-axis
6. Rotational position about the Z-axis

• These six coordinates are know as the six degrees of freedom of a three-dimensional object.As the double-headed arrows indicate,the translational and rotational positions can vary in either direction with respect to each of the three axes.To completely prevent movement,all six degrees of freedom must be restricted.
• These are the locators which arrest the 4 degrees of freedom by four ribs juctional together.These are of following type especially used for mold designs.

CONCLUSION:

• Creation of the car interior door trim is designedusing the given class A surface as the input and class B and C surface created with the help of class A surfaces by using the given master section attachement features i.e.heat stakes,flanges,dog house,locators and push clips are created using the design rule.

CLASS A DRAFT ANALYSIS:

SOLID PART DRAFT ANALYSIS:

DOOR TRIM PANEL ASSEMBLE:

ISOMETRIC VIEW

FRONT VIEW:

TOP VIEW: