Week 11 - Final project

AIM: To develop a Door Trim Panel from the given class A and master sections and also create the attachment features.

OBJECTIVE:

• To create the class B & C surfaces from the given class A surface for all components of the door trim
• To form a solid body i.e. thickened part for all components
• Refer the master sections for nominal thickness and to develop the B side or attachment features
• To create the tooling axis and perform draft analysis
• To create the mounting features as per design guidelines in the industry and with master sections
• Apply the material details

INPUTS:

CLASS A SURFACE:

MASTER SECTIONS:

PROCEDURE:

• Download the input files for the class A surface and master sections, study the inputs provided
• In Catia create a product file and name it as Door Trim Panel
• In that create part files to add all the components of the Door Trim Panel i.e. the Arm Rest, Lower Substrate, Bottle Holder & Map Pocket
• Next step is to create the tooling axis for the class A surface of each component
• Check for any disscontinuities in the class A surface, if found make the required improvements
• We would get the class B surface by offsetting the class A surface at a distance of 2.5mm
• Next step is to create the class C surface for which first extract the edges of the class A and sweep them at a certian distance considering 3° draft angle
• Then join all the three surfaces and trim the unwanted faces to form a single plastic component
• Now in the part workbench use the closed body command to form a solid component
• Follow the similar procedure to develop all the other components of the Door Trim Panel i.e. Lower Substrate, Bottle Holder & Map Pocket
• Now next we need to develop the attachment features or the B side features like flanges, Heat Stakes, Screw Bosses & Dog House
• We need to follow the master sections and the design guidelines in order to create the attachment features wherever required on the panel
• Flanges will be required on the Arm Rest and the Bottle Holder for the purpose of mounting
• To create flanges sketch the profile and pad it then translate it to the required locations
• Add minimum fillet of 0.25mm on the edges of the flanges
• Heat Stakes will be required on the Lower Substrate
• Follow the similar process as flanges to create the heat stakes

General guidelines that need to be followed while designing the bosses:

• Draft - 0.5 degrees on walls of boss
• Thickness - Typically 40%* of the nominal wall at the base.
• Height to Diameter Ratio - 3:1
• Radii - 0.25mm maximum radii.
• Sketch the circular profiles and pad till 12mm length considering the 3:1 ratio
• Provide 0.5° draft on the surface with the tooling axis as pulling direction
• Provide fillet with 0.25mm radius on all edges

General guidelines that need to be followed while designing the Dog House:

• Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ).

• "C" is where the doghouse contacts the backside of the surface

• Height of ( B ) should be between 3.0 – 6.0 mm

• Sketch the dog house profile and extrude
• Add thickness of 2mm
• Provide 0.5° draft on the faces with side the tooling axis as pulling direction
• To form the "C" profile offset the base at 4mm and extrude the dog house then offset it by 1mm use trim to get the profile (The length for C will be 1mm)
• Then split it with the thickned solid
• Provide draft on the inner faces
• Give 1mm fillet on inner surface of house and 3mm on outer

ARM REST:

CLASS A

CLASS A & B

CLASS C

FINAL SOLID COMPONENT:

ARM REST WITH ATTACHMENT FEATURES:

LOWER SUBSTRATE:

CLASS A

CLASS A & B

CLASS C

FINAL SOLID COMPONENT

BOTTLE HOLDER:

CLASS A

CLASS A & B

CLASS C

FINAL SOLID COMPONENT

MAP POCKET:

CLASS A

CLASS A & B

CLASS C

FINAL SOLID COMPONENT

ATTACHMENT FEATURES:

FLANGES

HEAT STAKES

SCREW BOSS

DOG HOUSE WITH PUSH PIN

FINAL DOOR TRIM PANEL:

RENDERS:

Applying the material as plastic on the door trim panel and creating the renders

CONCLUSION:

By working on this project I was able to apply my plastic component design knowledge which I had gained while learning this course to develop the Door Trim Panel considering the inputs(class A & master sections) as like in OEM and tier1 companies.