Week 11 - Final project
ANSWER:
AIM:
Development of a Door Trim panel
Creation of CAD model considering following inputs as like in OEM and tier1 companies
- a) Class A surface
- b) Nominal thickness: Refer master sections
- c) Attachment strategy
software used: CATIA V5
All sketches should be iso constrained
ensure proper tree-structured geometrical sets should have a proper name based on the sketches present inside of it
Create thickened part using the master section for reference
Create the mounting features as per design guidelines in the industry and with master sections
Creating Draft analysis & Tooling analysis
Creation of parting lines and check tooling feasibility.
INPUT CLASS A SURFACE:
Since the input class, CLASS A surface is containing four different parts(class A). So class b and c for all the surface has been created in a separate part. Also performing draft analysis and tooling axis separately. finally, all the surfaces have assembled together into one product
CREATION OF TOOLING AXIS ON THE LOWER SUBSTRATE:
Draft analysis in CATIA is a command that is used to detect if the part you drafted will be easily removed from the mold.
it is performed based on color ranges identifying zones on the analyzed element. Most the industries is using a minimum draft angle is 3 degree
PROCEDURE:
Check all the boundaries whether it has connected or not.
Check the model visually & choose the best tooling direction which should be easy to draft.
After analyzing the above model the best tooling axis is the y-direction.
CREATING THE TOOLING AXIS:
Create a point on the center of gravity of part by using the measure inertia command and insert an axis system on the point
as shown below
CREATION OF TOOLING AXIS – BOTTLE HOLDER PROCEDURE:
Check all the boundary whether boundaries are closed
After analyzing the above model, we have to create a tooling axis on YCheck the model visually & choose the best tooling
the direction which should be easy to draft.
CREATION OF TOOLING AXIS :
Create a point 1 and insert an axis system on the point 1 as shown below
Create an intersection on the XY plane for the given surface
create a point to point line
Add a bisecting line as shown below by the reference of two lines created above and named as tooling face X direction.
Create an intersection on the ZY plane for the given surface.
Create a point-to-point line as shown below.
Add a bisecting line as shown below by the reference of two lines created above and named tooling facing in the Y direction.
Add bisecting line by the reference of tooling facing x-direction and tooling facing y-direction and named as tooling axis.
CREATION OF TOOLING AXIS FOR DOOR ARM REST:
First, check all the boundaries of the given surface Check the model visually & choose the best tooling direction which should be easy for the draft.
After analyzing the above model, there is a chance for undercut when we consider the tooling axis from z.So we have to create
tooling axis on x,y, and also z.
Create a point and insert an axis system on the point 1 as shown below
Create an intersection on the ZX plane for the given surface
create a point-to-point line as shown below.
Add a bisecting line as shown below by the reference of two lines created above and named as tooling facing X direction.
Create an intersection on the ZY plane for the given surface
create a point to point as shown below
Add a bisecting line as shown below by the reference of two lines created above and named as tooling facing Y direction.
Add bisecting line by the reference of tooling facing x-direction and tooling facing y-direction and named as tooling axis
CREATION OF SSIDE TOOLING AXIS:
Create a point on the surface and create a line using point direction, use direction as a y-axis.
Drag a compass and place it on-axis that we created. Adjust the compass till we get the correct view. lock the orientation of the compass.
Modify the above line by changing the direction along with a compass
CREATION OF SIDE TOOLING AXIS X:
Create a point on the surface and create a line using point direction, use direction as a y-axis.
Drag a compass and place it on-axis that we created. Adjust the compass till we get the correct view. lock the orientation of the compass.
Modify the above line by changing the direction along a compass
CREATION OF TOOLING AXIS FOR THE UPPER SUBSTRATE:
First, check all the boundaries of the given class surface.
Check the model visually & choose the best tooling direction which should be easy for the draft.
After analyzing the above model the best tooling axis is the y-direction.
CREATING THE TOOLING AXIS:
Create a point on the center of gravity of part by using the measure inertia command and insert an axis system on the point
as shown below
create a point-direction line parallel to the y axis and named TOOLING AXIS as shown below
DRAFT ANALYSIS:
To perform draft analysis open customized view parameters and choose the material Insert a feature draft analysis by following these commands I insert>analysis>feature draft analysis.
Align the compass on the tooling axis that we created Open the color scale and enter the value is 3 deg. If the whole body is green that all the faces are greater angle than the provided angle
DRAFT ANALYSIS FOR A BOTTLE HOLDER:
DRAFTY ANALYSIS FOR DOOR ARM REST:
ALONG X-AXIXS:
ALONG Y- DIRECTION:
ALONG Z- DIRECTION:
DRAFT ANALYSIS ON A LOWER SUBSTRATE:
CREATION OF CLASS B SURFACE:
Insert a new geometrical set. Measure the value of thickness in the master section. The value is 2.5mm Offset the class A surface to 2.5mm. Check all the sub-elements are formed if not try to fix it locally
B SURFACE FOR BOTTLE HOLDER:
B SURFACE FOR THE DOOR ARMREST:
B SURFACE FOR THE UPPER SUSBTATE:
CREATION OF CLASS C SURFACE:
Analyze the class A once where the sweep is easier to create towards tooling direction Create a boundary using limitation points wherever possible for sweep Sweep the above boundaries for industrial standard 3 degrees towards tooling axis
Now Create the c surface by using a multisection solid where the sweep cant perform. Create a point on the curve as shown below and Create a line by using point to point line.
Split both surfaces by using the split command Create a boundary by using on the class a surface that is going to perform multisection surface.
Join the surfaces by using a multisection surface By using the same method create the c surface wherever the sweep is not possible After, join all the c surfaces Using the same method create c surfaces for all the parts
C SURFACE OF LOWER SUBSTRATE:
CLASS C SURFACE OF THE BOTTLE HOLDER:
CLASS C SURFACE OF THE DOOR ARMREST:
LOWER SUBSTRATE CLASS C SURFACE CREATION OF B SIDE ATTACHMENT FEATURES DOG HOUSE:
Extract the surface that we going to create a dog house Insert an axis system. use positioned and draw a dog house sketch
Sweep the sketch to 1.5 degrees in the direction of the main tooling axis Add thickness to the above sketch of 2.5mm by using thickened surface
DOG HOUSE RULE:
B=4mm t=2.5mm C=0.4 * t=1mm
Extract the sweep and offset to b=4mm and c=1mm in all directions like the below
Trim the portion to get the required sketch Draft to 5 degrees along the second tooling axis Add fillet to all faces
Assemble the doghouse to lower substrate solid Translate the doghouse to wherever we need
To place a pushpin on the doghouse create ribs to the doghouse Trim the ribs with a doghouse
HEAT STAKES:
Heatstakes is known as thermoplastic staking is the process of joining two dissimilar metals together Extract the surface that we going to create a heat stake
Use positioned sketch and draw a heat stakes sketch
Use pad commands for the sketch to till we are required to Draft the stakes minimum of 0.5 degree
Add fillet 0.3mm o all faces
Assemble the heat stake to lower substrate solid
Maintain a 50mm minimum between two heat stakes Translate the heats stakes to wherever we need,
Trim all heat stakes with lower substrate solid
LOCATORS:
Extract the surface that we going to create the locator Use positioned sketch and draw a locator sketch
Use pad commands for the sketch to till we required Draft the locator for a minimum of 0.5 degrees Add fillet 0.5mm o all faces
Assemble the locator to lower substrate solid
Maintain a 50mm minimum between two locators Translate the locator to wherever we need Trim all heat stakes with lower substrate solid Maintain a height more than the heat stake.
CREATION OF THE FLANGES:
Create a flange for the attachment of heat stakes and locators at the lower substrate.
WEIGHT OF THE COMPONENT:
Apply material plastic to the product
Use the measure command to calculate the weight of the product
CALCUALTION:
Lower substrate=0.5kg Bottle holder=0.266kg Arm rest =0.159kg Upper substrate=0.181kg
The total weight of the product is =1.123kg DRAFT ANALYSIS REPORT OF UPPER SUBSTRATE
DRAFT ANALYSIS FOR THE BOTTLE HOLDER:
DRAFT ANALYSIS FOR THE DOOR ARMREST:
DRAFT ANALYSIS RFOR THE LOWER SUBSTRATE:
CREATION OF PARTING LINE:
A parting line is used to the difference between core and cavity
(NOTE = THE PARTING LINE BELOW IS CREATED WITHOUT ATTACHMENT)
SOLID MODELS:
ALL VIEWS:
TREE STRUCTURE:
CONCLUSION:
The door interior part has been created from the inputs of class A surface along with the master section by following the design rules followed by the tier 1 and OEM companies.
========================== THANK YOU =============================