Week 11 - Final project
Aim:
To crate a CAD Model (Door Trim Panel) with attachment features considering features considering the given inputs, design rules and following the OEM standards.
This Project explain in brief regarding the Design life cycle followed in automotive industry by working on practical Model car interior door trim which is a car interior trim part. In this report we have explain about the steps followed to create a solid body of the piller cover taking Class A Surface as input and creation a Tooling axis and B surface with resect to the Class A surface and Creation of Class C surface and also the Draft Analysis. The attachement features also designed and reported as per given master section considering all the design rules for the creation of ribs and doghouse.
Procedure:
THE GIVEN INPUTS IS DIVIDED INTO 4 PARTS
- Lower Subsrate
- Map Pocket Upper Part
- Map Pocket Lower Part
- Arm Rest Part
Methodology:
- Class A surface extraction
- Creation of different Geometircal sets for each compoent such as lower substrate, map pocket (Upper and Lower part), armrest part
- Tooling Axis / Side Core Axis Creation
- Creation of Flanges
- Creation of Class B surface
- Creation of Class C surface
- Joining of Class A,B and C surface
- Forming a Solid Body
- Attachment features creation
- Performing Draft Analysis
1. Lower Substrate:
CLASS A SURFACE
TOOLING AXIS:
Tooling Direction is basically the direction that the core pulls apart from the cavity. And some components have ribs, pockets, walls.... are going to be drafted based on the Tooling Direction. So make sure the tooling direction which is cover all phases of the components and Core pull apart from the Cavity, nice and clean.
In this case, in Y-direction clear all faces. So to create the tooling axis in Y-direction, we first need to create a point and using this point create a line giving direction in the Y-axis. This line will give us the Tooling Axis.
Draft Analysis on Class A surface:
The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.
- To perform the darft analysis the view parameters are first set to material mode.
- then go to insert -analysis-feature draft analysis, the following window will be appeared.
- First select the axis system and drag the axis system to the tooling axis and lock the orientation. This axis system defines the draft direction according to the tooling axis
- Switch on the colour scale and set the draft value 3 degree using colour scale and it will be displayed in green colour any draft angle below 3degree will be shown in red colour.
- Now select the runing point tool to measure the draft angle at the various locations.
CLASS B SURFACE:
To create the Class B surface, the Class A surface is offset by 2.5mm (since the thickness of the component is 2.5mm). From the master sections which is given to us as input, we can measure the thickness of the componet.
CLASS C Surface:
To create a Class C surface firt extract the boundaries of the Class A surface.
After extracting the boundary, we need to perform a smooth (max. Deviation as 0.001mm) opertion on it to create a continuous tangents surface.
Now using the 'sweep' option create the C surface by sweeping the boundary of the Class A surface at an angle of 3deg out words to the tooling direction
Joining Surfaces:
To form a closed surface we first need to join the Class A surface with the Class C surface and then trim this joined surface with the Class B surface to get the final output.
Forming a Solid Body:
Since these surfaces are hollow, we need to close them to form a thick solid componet.
Using the "CLOSE SURFACE" option in PART WORKBENCH, a solid body from the closed surface can be formed.
2. Map Pocket Upper and Lower Part:
CLASS-A surface;
Now again from the input which was given to us, we need to extract the CLASS-A surface for the Map Pocket Upper and Lower Part separately in a different geometrical set.
LOWER PART
TOOLING AXIS:
DRAFT ANALYSIS:
CLASS B SURFACE:
CLASS C SURFACE:
JOINING SURFACES:
SOLID BODY:
Creating Flanges:
Flanges are needed to join the componets. Following the master sections, we can create these flanges and attach them to the solid body.
UPPER PART:
CLASS A SURFACE
TOOLING AXIS:
CLASS B SURFACE
CLASS C SURFACE
JOINING SURFACES:
SOLID BODY
CREATING FLANGES
Flanges are needed to join the componets. Following the master sections, we can create these flanges and attach them to the solid body.
DOOR MAP POCKET UPPER PART WITH FLANGES
4. Arm Rest Part:
To create the surfaces and forming a close body similar steps need to be performed as mentioned for the above parts. But to create a proper tooling axis for Arm Rest Upper Part, we need to adjust the tooling axis since this component cannot ne cleared in 90 deg to any (X,Y and Z) of the directions.
For the Arm Rest Part, a side core axis is also required along with the main tooling axis.
CLASS A SURFACE
TOOLING AXIS
In this case the main tooling axis doesent clear the all faces of the part. So we need sliding axis for clear the pocket area in door arm rest
MAIN TOOLING AXIS
SIDE TOOLING AXIS
DRAFT ANALYSIS
CLASS B SURFACE
CLASS C SURFACE
JOINING SURFACES:
SOLID BODY
CREATING FLANGES
Flanges are needed to join the componets. Following the master sections, we can create these flanges and attach them to the solid body.
Attachment features creation:
Heat Stakes:
Heat Stakes are used to join two or more parts that are made of plastic with the help of heat staking process. Heat staking process involves deformation of the platic material using heat and force to fix it with the other parts.
To create the heat stakes, we need to create a sketch with 2 circles of diameter 5mm and 7.5mm respectively. Now pad this sketch to form a solid and give it a draft of 0.5 degree.
Points are needed to position these heat stakes. Onces all the points are created, the solid body of the heat stake can be copied and paste on the tree structure multiple times (depending on the requirement, heat stakes need to be copy-paste).
Now using the translate option move these heat stakes from one point to another
Dog House:
The Dog House is an engineering feature that is used in the plastic trim design. It is used as a supporting feature for other engineering features like snaps, locators, push pins etc. that are mounted on the Dog house to increase their strenth and also to avoid the sink marks.
To create the Dog House, we first need t create a sketch that is rectangular with one side is open and then extrude it
Now using thicken option in PART WORKBENCH, given it a thcikness of 2mm to form a solid.
To get the inner shape of the Dog House the following Design Rules are followed.
- Doghouse wall thickness at the intersection of the part wall (c) should be 40% or less than the main wall stock (T).
- Height of (B) should be between 3.0 - 6.0 mm
TOOLING AXIS AND DRAFT ANALYSIS
Push Pins:
Push Pins are used for joining one component to another and are attached to the Dog House.
To create a Push Pin a sketch is drawn following the below details.
DOG HOUSE WITH PUSH PIN
DOGHOUSE WITH PUSH PIN ON DOOR LOWER SUBSTRATE
DOGHOUSE WITH PUSH PIN ON DOOR MAP POCKET
Draft Analysis on Door Lower Substrate
Draft Analysis on Door Map Pocket
Draft Analysis on Door Arm Rest
MAIN TOOLING AXIS
SIDE TOOLING AXIS
FINAL CAD MODEL
TREE STRUCTURE
Result:
A Door Trim Panel with engineering features using the master section and surface as an input has been successfully created and draft analysis has also been performed for the same.