Week 11 - Final project

DEVELOPEMENT OF A DOOR TRIM PANEL

AIM

• TO CREATE B & C SURFACE FAR A GIVEN A SURFACE
• TO DEVELOPE ALL ENGINEERING FEATURES ( PUSH CLIP,DOG HOUSE,HEAT STAKE,FLANGES,SCREW BOSS) FOR A GIVEN COMPONENT

ALL FEATURE SKETCHES AND THICKNESS FOR THE COMPONENT ARE TAKEN FROM THE MASTER SECTION

GIVEN SURFACE

DEVELOPED SURFACE

TOOLS REQUIRED

1 SURFACE WORKBENCH TOOLS

2 PART WORKBENCH TOOLS

SEQUENCE OF OPERATION

1 TOOLING AXIS CREATION

2 A SURFACE EXTRACTION & CHECKING DRAFT ANALYSIS

3 B & C SURFACE CREATION & CHECKING DRAFT ANALYSIS

4 B SIDE FEATURES CREATION ( PUSH CLIP,DOG HOUSE ,HEAT STAKES,FLANGES,SCREW BOSS) & CHECKING DRAFT ANALYSIS

PROCEDURE

1 TOOLING AXIS CREATION

WHAT IS THE TOOLING AXIS

THE TOOLING AXIS IS THE THAT DEFINES THE PULLING DIRECTION OF THE MOLD.

I CREATE A 3 TOOLING AXIS TO CLEAR THE DRAFT FOR THE COMPONENT.

TOOLING AXIS FOR MAP POCKET & LOWER SUBSTRATE

TOOLING AXIS FOR ARM REST & BOTTLE HOLDER

2 A SURFACE EXTRACTION & CHECKING DRAFT ANALYSIS.

BEFORE EXTRACTING THE a SURFACE LETS UNDERSTAND WHAT IS A SURFACE AND HOW IT DEVELOPS IN OEM'S

IN OEM'S THERE IS A SEQUENCE OF OPERATION FOR EVERY PRODUCT IE DESIGN LIFE CYCLE.

• CONCEPT SKETCHES
• CLASS A-CREATION
• CLAY MODELING
• NPD CAD

THE CONCEPT SKETCH TEAM CREATED A NEW DESIGN ON PAPER TAKEN INPUTS FROM THE FEASIBILITY CHECK & CONCEPT VALIDATION TEAM

AFTER APPROVING THE DESIGN THE STYLING TEAM TAKES PLACE AND CREATE THE A SURFACE WITH THE HELP OF ALIES SOFTWARE FROM THERE NPD TEAM DESIGN THE COMPONENT FOLLOWING ALL THE DESIGN PRINCIPLE AND ENGINEERING FEATURE FOR THE PRODUCTION BY USING DIFFERTENT SOFTWARE

I DIVIDED THE SURFACE INTO 4 SURFACES FOR THE CREATION OF B & C SURFACE AND B SIDE FEATURES THOSE ARE MAP POCKET,LOWER SUBSTRATE, ARMREST,BOTTLE HOLDER BY USING MULTIPLE EXTRAVT COMMAND

I CHEKED THE BOUNDARIES AND DRAFT ANALYSIS WITH THE TOOLING AXIS FOR THE A SURFACE.

ARM REST

AS YOU SAW,IN THE IMAGE THERE IS A BOUNDARY TO REMOVE THAT I EXTRACT THE COMPONENT INTO 2 SUB COMPONENTS AND EXTRAPOLATE THE EDGE AND MAKE THE TRIM TO GET A PERFECT A SURFACE

DRAFT ANALYSIS

AS YOU SAW IN THE IMAGE IN THE MAIN TOOLING AXIS THE TOTAL COMPONENT IS NOT CLEARING THE DRAFT SO WE HAVE TO CREATE A LIFTER AXIS TO CLEAR THE FACES

THE TOTAL A SURFACE IS CLEARING THE DRAFT ANALYSIS

LOWER SUBSTRATE

DRAFT ANALYSIS

THE TOTAL A SURFACE IS CLEARING THE DRAFT ANALYSIS

BOTTLE HOLDER

DRAFT ANALYSIS

AS YOU SAW IN THE IMAGE THERE IS A RED COLOR AT SOME SPORTS AND THE RUNNING POINT VALUE IS SHOWING 0 DEG VALUE BECAUSE THOSE ARE SHARP EDGES TO CLEAR THAT WE HAVE TO INFORM TO RESPECTED A SURFACE TEAM AND GET THE CHANGED COMPONENT AND WORK ON IT.

THE TOTAL A SURFACE IS CLEARING THE DRAFT ANALYSIS.

MAP POCKET

DRAFT ANALYSIS

3 B & C SURFACE CREATION & CHECKING DRAFT ANALYSIS.

WHY DO WE CREATE B & C SURFACE?

THE A SURFACE WHICH WE RECEIVE DOES NOT HAVE ANY THICKNESS AND ANY DESIGN PRINCIPLE.IT'S JUZT AN IMAGINARY SKETCH AND WE CAN NOT MANUFACTURE THAT COMPONENT THAT'S WHY WE CREATE B & C SURFACE BY FOLLOWING ALL THE DESIGN PRINCIPLES, AND IT'S EASY TO MANUFACTURE

BY USING SURFACE WORKBENCH COMMANDS I CREATED THE B & C SURFACE

ARM REST

AFTER CREATING ALL SURFACE I USED THE JOIN AND TRIM COMMANDS TO GET THE SOLID BODY

HOW CAN WE SAY THAT ITS A SOLID BODY.

BY CHECKING THE BOUNDARY FOR THE COMPONENT ,IF IT SHOWS ANY BOUNDARY THEN THE COMPONENT IS NOT A SOLID BODY,IF IT DOESN,T SHOW ANY BOUNDARY THEN WE CAN SAY IT'S A SOLID BODY

LOWER SUBSTRATE

MAP POCKET

BOTTLE HOLDER

4 B SIDE FEATURES CREATION & CHECKING DRAFT ANALYSIS

FEATURES ARE COMMONLY FOUND IN INJECTION MOLDING DESIGNS.THEY ARE USED TO AID I N THE ASSEMBLY OF MOLDED PARTS BY PROVIDING A CHANNEL BETWEEN THE PLASTIC COMPONENT AND SHEET METAL.SOME OF THE FEATURES ARE

• RIBS
• FLANGES
• HEAT STAKES
• SCREW BOSS
• DOG HOUSE
• PUSH CLIPS

THESE FEATURES ARE CREATED WITH HELP OF MASTER SECTION WHICH IS GIVEN WITH THE A SURFACE

THE REF MASTER SECTION SAYS THAT THIS COMPONENT HAS FLANGES ON ARM REST AND MAP POCKET,SCREW BOSS ON ARM REST,DOG HOUSE PUSH CLIP ON LOWER SUBSTRATE AND MAP POCKET HEAT STAKES ON LOWER SUBSTRATE AND MAP POCKETS

FLANGES ON MAP POCKETS AND BOTTLE HOLDER

FLANGES CREATING ON ARM REST

HEAT STAKES IN MAP POCKET

BY USING THE EXTRACT COMMAND I CREATED THE REF SIZE OF THE HEAT STAKE FROM THE FLANGES AND EXTRUDED IT TILL THE SURFACE PASSED AND THICKNES THE SURFACE

IN THE SAME MANNER FOR THE LOWER SUBSTRATE ALSO

SCREW BOSS CREATION ON ARM REST

DOG HOUSE AND PUSH PIN

TOTAL DRAFT ANALYSIS OF THE COMPONENTS WITH THE FEATURES TREE

THE PART IS READY FOR MANUFACTURING

TREE STRUCTURE