Week 11 - Final project

REPORT

ABSTRACT: In this project of door trim panel I was provided with Class A aesthetic surfaces and in the final output I have to create the proper solid body while following every design rules and regulations and checking for every locations at every required area. In this project I ought to use every knowledge and experience that I gained and learned while completing this course from scratch upto this level. In this final project I have to apply basic part design knowledge to final assembly design knowledge to achieve the required results.

INTRODUCTION: The final project of this course is also known as door trim panel have four major components and all the componenets have important B Side Features. One of the important features is known as flanges is to be drawn in every component except the base component known as lower substrate. The designing of flanges is to get connected with the lower substrate through heat stakes.

After the completion of B side features and other important modifications, the final activity is to do the assembly design of the push pins on the Modified Dog House that is created on the lower substrate.

The Overall Aesthetic look of the final Door Trim is be like:-

Above here is final front facing of solid body of Door Trim. This is solid aesthetic surface in which all the door sections, components and important Bside features are attached at the back of it. The image of the back-side of the door is attached here:-

METHODOLOGY

CREATION of SOLID COMPONENTS:

1. DOOR ARM REST: The solid surface of the door arm rest has a thickness of 2.5 mm. The solid body is used to provide support and rest to the arm. There are multiple flanges attached to it for connection to the lower substrate through the heat stakes. There is parting line and solid surface for perfect manufacturing and location setting for core and cavity. There is tooling axis is also designed into it for the core and cavity path during the injection moulding.

With all B-Side features visible from bottom side of the door arm rest.

2. MAP POCKET: The position of the map pocket is just below to the door arm rest. It is the major part which is connected to the both lower substrate and door arm rest of the door panel. The thickness of the door arm rest is also 2.5 mm and the major B side features attched on it are flanges of 2.5 mm thickness. The location final orientation of the map pocket is like:-

The creation of the parting line is done with tooling axis in order to provide a proper guide and reference to the core and cavity of the respective injection moulding system.

3. Bottle Holder: The use of bottle holder in Door trim design is took keep bootle. The aesthetic surface of the bottle holder has a calculated depth for holding the bottle of considerable size in proper manner. The design of the solid surface is given in the below design is as:

The parting line along the intersection of all A,B and C surfaces help us to create the parting line and that eventually choose the limits for core and cavity along with the path with the help of tooling axis.

4. Lower Substrate: The lower substrate is the also act as the back base of the whole door trim. It is the biggest part which contains the other important B side features like Heat Stakes and dog house. The design and developemnt of the lower substrate is the get connect with every other part of the main door trim design. It is the bottom most part of the door which further attched with extra components like Speakers. The design for lower substrate is extended from the top side as it can get connect with upper side substrate easily.

The solid body design of the lower substrate body is be like:

The designing and of lower substrate form injection moulding we need proper tooling axis as well as parting surface to get along with the proper limits without any intersection and mistakes.

The final image of the parting line for lower substratein the plane is as:

ONJECTIVE

B SIDE FEATURES

The developemnt of B side features is one of the most important and time consuming method in designing of Door Trim Design. All the mentioned B Side features are very important as they used in connectiong as well as joining of the main surfaces to the other extended surface. The major Time consuming portion is extra modification and designing minute and important details on all over the body.

All these b side features are important as they protect the whole surface from the plastic defects. They also extend the life and strength of the Solid B side body. There are four major B side features which is used here for proper connctivity and design are

1. Flanges

2. Heat Stakes

3. Dog Houses

4. Ribs

1. Flanges: The design of flanges is to extend and increase the surface height so that it can connect with the other surface easily. The thickness of the flange is just same as the thickness of the major component in which it is designing for the extension. The extension of the flanges is 37.5 mm and it also contain a hole of 7.6 mm. The hole diameter ideally should be 7.5mm but the tolerance and other factors extend the surface hole size of 7.5 to 7.6. The major development of the flanges is done on the initial and thickness at the final state. The solid image of flanges like:

2. Heat Stakes: The next major portion of the B side features in Door Armrest is heat stakes. The importance of heat stake is high but secondary, It is used in lower parts of in order to get connect with the flanges. All the heat stakes are well positoned and drafted at angle of 0.5 degree. All the designing of heat stkes in orded to get get connected at every required positons. The solid body of heat stakes are like:

3. Dog-House: The major goal for designing the dog house is to give a proper extension and save the product from getting any sink marks. A sink mark cut is also placed in the bottom of dog house to protect it properly. The initial goal is achived by placing the dog house at nominal size or required size. It can also be used for providing an minimal protection and design allocation. The solid body design of the dog house is be like:

4. Ribs: The final B side feature which play very important role in every location. The main aim for providing the ribs in B side feature is to provide a proper support system to that feature. It is attached in every other B side feature which is created here. All the placements and locations for the ribs decided on the basis amount of support is required. It is placed every where and the height of the ribs is change according to the requirement of support needed to the structure. The solid Structure of Ribs at all the present areas be like:

RESULTS and ANALYSIS:

1. Door Arm Rest: The first observational result is in door arm rest and the analysis of the final result is done of the Class A aesthetic Surface and Final body. The result of draft analysis for the both the solid surface and aesthetic A surface is as follows:

This is the result of the draft analysis done on the soild surface of the door arm rest at an angle of 0.453 degrees. The draft analysis of the class A aesthetic surface is as follows:-

The result of draft analysis of the aesthic Class A surface of the door arm rest. The analysis of the draft anagle is done through the tooling axis. The optimum result that is obtained is angle of 0.453 degree.

2. Map Pocket: The result and analysis of the map pocket is done with the help of drafting angle that is provided during the manufacturing of the map pocket. The result of draft analysis for both of the the solid surface and class A surface is as:

The draft angle for the solid body of the map pocket is 0.453 degree. The Class A surface which also act as aesthetic surface for the map pocket is also undergoes draft analysis. The final result of the draft analysis is as:

3. Bottle Holder Design: The results and analysis of the bottle holder design is done with the help of tooling axis which is used to give the proper dimensions and angles to draft and through and cavity properly. The draft is required at every critical surfaces to get ejected from the core and cavity. The draft analysis of the solid bottle holder surface is as:

The class A given surface of the Door trim for the bottle holder is also drafted and the updated result is be like:

4. Lower Substrate: Due to its large surface and some extended areas the design and developemnt of the lower substrate is little difficult. So the design analysis for the lower substrate is also little complex. The final draft analysis for the lower substrate requires a proper angled tooling axis at the considerable location. The final approach for the designed surface is as:

The same design is taken references from the aesthetic class A surface . The Class A Surface of the Door trim design is shown here. The final draft of the Class A surface be like.

SUMMARY

The final conclusion for designing the door trim is to generate a proper door structure of Door which can be attached in every condition. The major objective behind the proper designing of the door trim body is to develop a proper door which is cost effective and the strength is at considerable amount which can withstand every possible crash and dent situation.

The secondary objective for this door trim panel design is to provide a luxury design in the class of the aesthetic surface. The major development is in the position and proper constant sup[port that is required to provide by the other B side features at proper time.