Challenge

Week 11 - Final project

NNidhin Joseph Raj I J14 Jul 2022

DESIGN FEA

GIVEN CLASS A ASSEMBLY

THIS IS A DOOR TRIM ASSEMBLY WHICH IS THE INNER SIDE PART OF THE DOOR THAT WE CAN REACH WHILE INSIDE THE CAR

WE CAN SPLIT THE SURFACES INTO 4 PARTS

PART 1

ARM REST

TOOLING DIRECTION

TOOLING DIRECTION IS DETERMINED BY TAKING CROSS SECTION BETWEEN PLANES AND THEN BISECTING THE LINES WE GOT FROM THE CROSS SECTIONS

CLASS A ,B AND C SURFACES

FINAL TRIM AMD CLOSED BODY

TOOLING DIRECTION FEASIBILTY USING DRAFT ANALSYSIS

MINIMUM DRAFT REQUIREMENT IS 3MM

PORTION TO MODIFY

THE PORTION SHOWING NEGATIVE DRAFT HAVE TO BE MODIFIED BY THE STYLING TEAM INORDER TO CORRECT THE DRFAT.

FINAL PART DRFAT ANALYSIS

PART 2

LOWER SUBSTRATE WITH TOOLING DIRECTION

TOOLING FEASIBILTY USING DRAFT ANALYSIS

REGIONS TO MODIFY

CLASS A ,B AND C SURFACES

FINAL TRIM AND THICK BODY

DRAFT ANALSYSIS

PART 3

UPPER DOOR SUBSTRATE AND TOOLING DIRECTION

DRAFT ANLSYSIS TO CHECK TOOLING DIRECTION

CLASS A, B AND C SURFACES

FINAL TRIM AND THICK BODY

DRAFT ANALYSIS

PART 4

BOTTLE HOLDER AND TOOLING DIRECTION

DRAFT ANLYSIS FOR TOOLING DIRECTION FEASIBILTY

CLASS A, B AND C SURFACES

FINAL TRIM AND THICK BODY

FINAL ASSEMBLY OF PARTS

B SIDE FEATURES

B SIDE FEATURES ARE USED TO ASSEMBLE THE PARTS IN A COMPONENT.MOSTLY B SIDE FEATURES CONSIST OF SCREW BOSS, HEAT STAKE,DOG HOUSE , RIBS ETC. THE B SIDE FEATURES STRENGTHENN THE AREA WHERE THE PARTS MEET.

SCREW BOSS

Screw Bosses find use in many part designs as a point for attachment and assembly. Most common use of cylindrical projections with holes designed to receive screws or threaded inserts or fasteners.

One critical parameter while designing screw boss is that one should avoid merging of screw boss to sidewall so as to avoid thick sections at side walls.

DOG HOUSE

While designing Ribs or screw boss, sometimes the counter part is at some distance up to which Ribs or screw boss cannot be designed because of the defect limitations or failure chances. In those cases where mating parts are at certain distance, Dog House serve the purpose of providing height to the Rib or screw boss.

In general, Dog House is a shape having certain height from Base wall where we can mount screw bosses over the Dog house to solve the mating purpose. Here, dog house is connected to base wall. So, we have to consider the wall thickness at Dog house and Base wall portion. For Solving that purpose and to avoid sink marks to opposite surface, Dog house is designed in such a way that it’s wall thickness must be within standard rule dimension. More information we can derive from below thumb rules.

RIBS

Ribs are thin, wall-like features typically designed into the geometry of a part to add internal support to walls or other features like bosses. In a similar fashion, gussets are support features that reinforce areas such as walls or bosses to the floor.

HEAT STAKE

Heat staking also known as thermoplastic staking is the process of joining two dissimilar materials together. In heat staking we use local heating and cooling to raise the temperature of plastic components and allow plastic reforming to be carried out. This reforming can be used in a wide variety of applications.