Week 11 - Final project
Generation of Class-C surface.
Class B Surface is generated by offsetting the Class A surface to the required thickness [2.5mm] and extrapolating it to make the trim easier.
Class C Surface is generated by extracting the boundary line of Class A Door Applique using Boundary Tool 
available in Operation Toolbar and generating the surface using Sweep option with required draft [min 3 deg] along the tooling axis.
INFORMATION FROM MASTER SECTIONS
1. Heat Stakes Inner and Outer Dia
2. Melting Clearance
3. Flange Total clearance.
Fixing methods and features
1. Dog House [with Technical Drawings] with Push pin clip
2. Heat Stakes[with and w/o Ribs]
Advantages of Heat Stakes:
- Performs in one machine cycle and motion rather than individual motions required for each fastener.
- Not need to change the Base material
- Creates almost no mechanical stress because it operates through a precise control and application of the temperature and pressure to cause the reforming of the plastic that it makes contact with.
- Better compared to Ultrasonic plastic Assembly where it uses ultrasonic vibration to generate heat and assembly process which have been known to effect or damage sensitive electronic components and cause cold solder joints or stress cracks in the printed circuit boards.
- Variety of Shapes are possible via customized design tools.
Heat Stakes with Ribs
Heat stakes with Ribs is created where the height between the flange and the surface of the Lower substrate is more than 12mm to provide strength to heat stake and for supporting the flange.
Heat stakes without Ribs
3. Locater [4-Way locater]
TOOLING AXIS AND DRAFT ANALYSIS
TOOLING AXIS: It is an Axis which indicates the direction in which the mould/cavity opens. It can also help in designing the component according to the drafting needs of an Industry.
COMPONENTS OF INTERIOR DOOR TRIMS
1.DOOR ARM REST
1. Door Arm Rest with Flanges as shown below
Tooling Direction and Draft Analysis of Door Arm Rest
CLASS A DRAFT ANALYSIS
FINAL PLASTIC COMPONENT [CLASS C ] DRAFT ANALYSIS
Draft Analysis of B-side Features of Door Arm Rest using Side Core Axis tool [Main Tooling Axis]
2.MAP POCKET
2. Map Pocket with Flanges as shown below
Tooling Direction and Draft Analysis of Map Pocket
CLASS A DRAFT ANALYSIS
CLASS C SURFACE DRAFT ANALYSIS
MAP POCKET WITH FLANGES DRAFT ANALYSIS
3. BOTTLE HOLDER
Draft Analysis of Class A Surface
Face that didn't clear Draft Analysis on Class A as shown below.
Draft Analysis of Class C surface.
Draft Analysis of Bottle Holder with Flanges
4. LOWER SUBSTRATE
Draft Analysis of Class A Surface
Draft Analysis of Class C surface
Draft Analysis of Lower Substrate with B-side Features [Heat Stake and 4way -Locater]
Draft analysis of B-side Features
Dog House
The face with red colour can be cleared with the side core axis as shown below in pink colour.
Main tooling Axis is shown in yellow colour.
FINAL INTERIOR DOOR TRIM OUTPUT WITH B-SIDE FEATURES AND FLANGES
