Week 11 - Final project
Development of a Door Trim panel
Aim: To Development a door trim panel following the design guidelines.
The door panel has evolved from a simple two-part system of latch and simple winding mechanism to a more sophisticated enclosure. Doors currently have an inner full-width panel consisting of electronic windows, central locking system, and speakers.
INTRODUCTION:
Door panels serve as an interface between the interior of the car and the inner workings of the door, and between vehicle occupants and the door. They are expected to meet a variety of design specifications regarding safety, aesthetics, and functionality. In addition, they are expected to continue the material theme of the dashboard and pillars while concealing intricate electrical and mechanical components for operating locks, windows, and other features. The door panel has evolved from a simple two-part system of latch and simple winding mechanism to a more sophisticated enclosure. Doors currently have an inner full-width panel consisting of electronic windows, central locking system, and speakers. These panels typically consist of a foamed core covered with either textiles or plastics.
DOOR TRIM PANEL CONSISTS OF FOLLOWING COMPONENTS:
- DOOR ARM REST
- INNER MAP POCKET
- OUTER MAP POCKET
- LOWER SUBSTRATE
- FLANGES
- HEAT STAKES AND DOG HOUSE
DOOR ARM REST
Isometric View
Front View
Side View
Top View
Draft Analysis:
Draft Analysis is done to analyze the draft angle .this allows us to verify whether the product will be easily removed from the tool .when designing a product they need to be angled slightiy so that the tool can be pulled away from the object easily without deformation or damage .This slight angle is called draft I have given the condition for draft angle with a maximum deviation of 3 degrees, anything within that limit is shown in green, whicn means that the part is producible.
INNER MAP POCKET
Isometric View
Front View
Side View
Top View
Draft Analysis
Draft Analysis is done to analyze the draft angle .this allows us to verify whether the product will be easily removed from the tool .when designing a product they need to be angled slightiy so that the tool can be pulled away from the object easily without deformation or damage .This slight angle is called draft I have given the condition for draft angle with a maximum deviation of 3 degrees, anything within that limit is shown in green, whicn means that the part is producible.
OUTER MAP POCKET
Isometric View
Front View
Side View
Top View
Draft Analysis
Draft Analysis is done to analyze the draft angle .this allows us to verify whether the product will be easily removed from the tool .when designing a product they need to be angled slightiy so that the tool can be pulled away from the object easily without deformation or damage .This slight angle is called draft I have given the condition for draft angle with a maximum deviation of 3 degrees, anything within that limit is shown in green, whicn means that the part is producible.
LOWER SUBSTRATE
Isometric View
Front View
Side View
Top View
Draft Analysis
Draft Analysis is done to analyze the draft angle .this allows us to verify whether the product will be easily removed from the tool .when designing a product they need to be angled slightiy so that the tool can be pulled away from the object easily without deformation or damage .This slight angle is called draft I have given the condition for draft angle with a maximum deviation of 3 degrees, anything within that limit is shown in green, whicn means that the part is producible.
FLANGES & HEAT STAKES AND DOG HOUSE :
Design rules for Screw Boss:
Consider using open boss designs for bosses near a standing wall. Avoid bosses that merge into sidewalls because they can form thick sections that lead to sinking. Instead, position the bosses away from the sidewall, and if needed, use connecting ribs for support. Consider using open boss designs for bosses near a standing wall.
1. Draft - 0.5 degrees on walls of boss
2. Thickness - Typically 60% of the nominal wall at the base.
3. Height to Diameter Ratio - 3:1
4. Radii - 0.25mm maximum radii.
Thus following all the above guidelines screw boss was created.
HEAT STAKES AND DOG HOUSE
Create the Dog House for the Door Trim considering the design rules mentioned in the video.
"C" is where the doghouse contacts the backside of the surface
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Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ).
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The height of ( B ) should be between 3.0 – 6.0 mm
DRAFT ANALYSIS:
The draft analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.
- This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.
These values are expressed in the unit as specified in tools >option > general > parameters > unit tab.
You can modify them by clicking on their corresponding arrow or by entering a value directly in the field. - The mapping texture accuracy depends of the video card used. Therefore, colors displayed on surfaces could be wrong according to the color scale, when the value displayed on the fly is right because the analysis is recomputed at the cursor location.
Sometimes, in the case of extremely closed values, it is recommended to switch to the quick mode to improve the color display accuracy. - The maximal draft analysis accuracy is 0.01 deg. According to the graphic card performance, this accuracy can be debased.
- The different mapping analyses of the same surfaces cannot be displayed simultaneously, even if you have set the mapping analyzes in no show. You need to visualize them one after the other.
Final product is show in the fig
