Week 11 - Final project
OBJECTIVE: objective for this project is to make half of the door trim panel in catia-V5 from the provided Class-A surface of the same.
ABSTRACT: This report contains a brief theory on design rules and the approach followed to achieve the final plastic product. Draft analysis report on all the class-A surface apart from the procedure to make the class-B and class-C surface is also mentioned.
APPROACH:
Our basic approach to make a plastic model from class-A surface should be:
- Run draft analysis
- Make tooling axis
- Make B surface
- Make C surface
- Trim all together and make it solid.
CLASS-A SURFACE
In automotive industry various teams works on various components, a car for example is not entirely designed by a single designer. There are many teams among which the task of making various components is distributed. And this is followed for every department of the industry. In this project we are given class-A surface which is designed in other software like Autodesk Alias, by a class-A designer. This is aesthetic surface and a lot of time, effort and good experience are demanded for making this continuous and a good flowing surface model. This is the major reason why, when we get this as input we are not allowed as a plastic designer to make any improvements in the class-A surface. Rather, it should be brought to the attention of the seniors which later is conveyed to the concerned team and take care of.
TOOLING AXIS
Tooling axis is the axis along which the core and cavity opens and closes. It is very important to define the tooling axis in the first step while designing a component as it is the main component which helps us to run draft analysis on class-A at initial stage to see if we can move ahead. Also for later stage, tooling axis is the direction along which class-C surface and the draft to the components is given.
In this model we have a tooling axis in the perpendicular direction to the entire door trim that is y-direction in the model. It is very evident that switch bezel will require a side core, so another tooling direction is made specifically for switch bezel. Apart from these two tooling axes we also have a side core tooling axis for dog house.
DRAFT ANALYSIS
Our first step before starting the model should always be to check is the surface has enough draft that it will not create any problems while ejecting from the mold. This seems like a big task as we have to foresee something that will come at very later stage. But this is done by a small process called draft analysis. This analysis tells us whether our component will be safely ejected in the tooling axis we have provided. Some components require side core where there are under undercuts, holes or projections on the side walls, so for this we need a different tooling axis and a different analysis is required to check those areas. Draft analysis shows color codes which are defined by the user for different values which also are defined by the user. These colors help us to analysis if the component is clearing the analysis and we are good to go ahead or not. In case the component fails the analysis for class-A then we have to submit the draft analysis report to the higher authority so that the surface of the component can be improved. Failing analysis simply means that the component does not have the required draft value it must have. In case our solid model which we develop, fails the analysis at some parts then we have to correct it ourselves.
We have to make sure that our entire model is green which means it is clearing the analysis. So we have to run analysis for class-A, solid model and other B-side features as every single component, regardless of its size should be ejected safely from the core.
DRAFT ANALYSIS REPORT ON CLASS-A SURFACE : -
CLASS A SURFACE OF LOWER SUBSTRATE : -
SOLID BODY OF LOWER SUBSTRATE : -
CLASS A SURFACE OF LOWER MAP HOLIDER : -
NOTE : - SOME PORTION ARE 0 ABD BELOW 3 DEGREE ANGLE NEED TO MODIFIED.
SOLID BODY OF LOWER MAP HOLIDER : -
CLASS A SURFACE OF UPPER MAP HOLIDER : -
SOLID BODY OF UPPER MAP HOLIDER : -
CLASS A SURFACE OF ARM REST : -
NOTE : - SOME PORTION ARE 0 ABD BELOW 3 DEGREE ANGLE NEED TO MODIFIED.
SOLID BODY OF ARM REST : -
REMSTERING OUTPUT OF DOG HOUSE : -
FINAL OUTPUT OF DOOR PANEL : -
