Week 11 - Final project

 AIM:

To develop a Door Trim Panel from the given class A and master sections and also create the attachment features.

OBJECTIVE:

• To create the class B & C surfaces from the given class A surface for all components of the door trim.
• To form a solid body i.e. thickened part for all components.
• Refer the master sections for nominal thickness and to develop the B side or attachment features.
• To create the tooling axis and perform draft analysis.
• To create the mounting features as per design guidelines in the industry and with master sections.
• Apply the material details.

Inputs

Class A Surface

Master Section

PROCEDURE:

• Download the input files for the class A surface and master sections, study the inputs provided.
• In Catia create a product file and name it as Door Trim Panel.
• In that create part files to add all the components of the Door Trim Panel i.e. the Arm Rest, Lower Substrate, Bottle Holder & Map Pocket.

• Next step is to create the tooling axis for the class A surface of each component.
• Check for any disscontinuities in the class A surface, if found make the required improvements.
• We would get the class B surface by offsetting the class A surface at a distance of 2.5mm.
• Next step is to create the class C surface for which first extract the edges of the class A and sweep them at a certian distance considering 3º draft angle.
• Then join all the three surfaces and trim the unwanted faces to form a single plastic component.
• Now in the part workbench use the closed body command to form a solid component.
• Follow the similar procedure to develop all the other components of the Door Trim Panel i.e. Lower Substrate, Bottle Holder & Map Pocket Now next we need to develop the attachment features or the B side. features like flanges, Heat Stakes, Screw Bosses & Dog House.
• We need to follow the master sections and the design guidelines in order to create the attachment features wherever required on the panel.
• Flanges will be required on the Arm Rest and the Bottle Holder for the purpose of mounting.
• To create flanges sketch the profile and pad it then translate it to the required locations.
• Add minimum fillet of 0.25mm on edges of the flanges.
• Heat Stakes will be required on the Lower Substrate.
• Follow the similar process as flanges to create the heat stakes.

General guidelines that need to be followed while designing the bosses:

• Draft - 0.5 degrees on walls of boss.
• Thickness - Typically 40%* of the nominal wall at the base.
• Height to Diameter Ratio - 3:1
• Radii - 0.25mm maximum radii.

• Sketch the circular profiles and pad till 12mm length considering the 3:1 ratio.
• Provide 0.5° draft on the surface with the tooling axis as pulling direction.
• Provide fillet with 0.25mm radius on all edges.

General guidelines that need to be followed while designing the Dog House:

• Doghouse wall thickness at the intersection of the part wall (C) should be 40% or less than the main wall stock (T).
• "C" is where the doghouse contacts the backside of the surface
• Height of (B) should be between 3.0 - 6.0 mm
• Sketch the dog house profile and extrude
• Add thickness of 2mm
• Provide 0.5° draft on the faces with side the tooling axis as pulling direction
• To form the "C" profile offset the bas at 4mm and extrude the dog house then offset it by Imm use trim to get the profile (The length for C will be 1 mm)
• Then split it with the thickned solid.
• Provide draft on the inner faces.
• Give 1 mm fillet on the inner surface of house and 3 mm on outer.

ARM REST

Class A

Class A&B

Class C

Final Solid Component

Arm Rest with Attachment Features

LOWER SUBSTRATE:

CLASS A 

CLASS A & B

CLASS C

FINAL SOLID COMPONENT

BOTTLE HOLDER:

CLASS A

CLASS A & B

CLASS C

FINAL SOLID COMPONENT

MAP POCKET:

CLASS A

CLASS A & B

CLASS C

FINAL SOLID COMPONENT

ATTACHMENT FEATURES:

FLANGES

HEAT STAKES

SCREW BOSS

DOG HOUSE WITH PUSH PIN

FINAL DOOR TRIM PANEL:

Conclusion:

By working on this project I was able to apply my plastic component design knowledge which I had gained while learning this course to develop the Door Trim Panel considering the inputs(class A & master sections) as like in OEM and tier1 companies.