Week 11 - Final project

Development of Door trim panel

Aim :

Create the Door trim panel by using the given class A surfaces and by refer the master section for thickness. And also create the required engineering features like Dog house, Flanges and Heat stakes. And assemble all parts using constrains.

Objective :

• Create Tooling axis for class A surface by using bisecting method.
• Draft analysis for Class A surfaces.
• Design the Class B surface, class C surface and closed surface and create solid body.
• Design engneering features like Dog house, Heat stakes and flanges.
• Draft analysis for final solid body.
• Assembly for Door trim panel.

Theory :

Tooling Axis :

Class-A surface is first analyzed to create the tooling axis or tooling direction that molds pull apart in injection molding. Tooling direction is important for plastic product design as it decides direction for mold seperation.

Step followed for creation of tooling axis :

• Reference point is first created on extracted surface.
• New axis system is deployed to plot clearance lines.
• The X-direction and Y-direction along the class-A were used to create tooling axis.
• Graphic properties of tooling axis were change before publishing.

Draft Analysis :

The Draft angle is the amount of taper for molded or cast parts perpendicular to the parting line. It can be measured in degrees. A functional part for injection molding has to have Drafts facing both cavity and core sides to reduce the risk of damage to the parts and ensure ejection. And also important is to overcome the vaccume forces by letting air in between the metal to the plastic for the part to relaese properly. Adding maintaining a decent cosmetic finish.

Draft should be a part of design for manufacturing and plastic product Designer should be aware of its need at the outset of the design process. This allows considerations for design requirement to be taken into account.

Nominal values for Draft angle :

• 3 Degrees is the nominal Draft angle.
• 7 Degrees for textured surface.
• At the minimum of 0.5 Degrees can be manufactured by special tools.But it will increase the manufacturing cost.

Given : (Class A surface - Master section)

Tooling axis Creation : (For lower substrate)

Steps as Screen shots :

The first step for creating tooling axis is find the hole or large flat surface on the class A surface because the area will be perpendicular to the tooling axis. so for this surface Y direction will be the tooling axis so we create the point on the flat surface as shown in figure.

Next step is to create the reference axis from Z direction by using sketch and bisecting line as shown in figure.

Similarly create the reference axis from X direction as shown in figure.

Now create surface by using the Extrude tool as shown in figure.

The intersection section of this surface will be the main tooling axis so using this intersection tool tooling axis is created as shown in figure.

Finally change the line type and line color for better visiblity as shown in figure.

Tooling axis for Upper substrate :

Tooling axis for Bottle Holder :

Tooling axis for Arm Rest :

Steps followed for Draft Analysis :

1. The part created has to be changed to material mode in display frame.
2. Compass is enabled and align it along with the tooling direction.
3. Lock command is then applied to fix compass along with tooling axis.
4. Color codes are classified and Draft angle is applied.
5. Running point analysis is used to display permissible draft angle.

Draft Analysis for lower substrate :

Draft Analysis for Upper substrate :

Draft Analysis for Bottle Holder :

Draft Analysis for Arm Rest :

Solid Part creation :

Upper substate :

Steps :

Given Class A surface :

Created Class B surface :

Created Class C surface :

Closed surfaces :

Solid Part : Upper substate

Solid Part : Lower substate

Solid Part : Bottle Holder

Solid Part : Arm Rest

Parting Line : Lower substrate

Parting Line : Upper substrate

Parting Line : Bottle Holder

Parting Line : Arm Rest

Creation of Engineering Features : (Dog House , Flanges , Heat stakes)

1. Lower substrate : (Dog house , 4 way locaters , Heat stake)

Tree Structure :

2. Upper substrate : (Flanges)

Tree Structure :

3. Bottle Holder : (Flanges)

Tree Structure :

4. Arm Rest : (Flanges)

Tree Structure :

Steps followed for Draft Analysis :

1. The part created has to be changed to material mode in display frame.
2. Compass is enabled and align it along with the tooling direction.
3. Lock command is then applied to fix compass along with tooling axis.
4. Color codes are classified and Draft angle is applied.
5. Running point analysis is used to display permissible draft angle.

Draft Analysis for lower substrate : (Main Tooling axis)

Draft Analysis for lower substrate : (Side core axis)

Draft Analysis for Upper substrate :

Draft Analysis for Bottle Holder :

Draft Analysis for Arm Rest :

Assembly :

Tools used :

1. Product Structure Tools

2. Move

3. Constraints

Assembly : Door Trim Panel

Iso-metric View :

Front View :

Side View :

Top view :

Class A Side view :

Class B Side view :

Conclusion :

Hence the Door trim panel by using the given class A surfaces and by refer the master section for thichness. And also created the required engineering features like Dog house, Flanges and Heat stakes. And assemble all parts using constrains is successfully done.