Challenge

Week 11 - Final project

MMohammad Shuhail U3 Oct 2022

Door Trim Lower Part

The design of the lower plastic component of an automobile door trim.

Input

Master Section

Class A Surfaces

Lower Substrate

Map Pocket

Armrest

Push Pin Clip

Closed Body

Parting Line

Armrest

Map Pocket

Lower Substrate

Challenges

Tooling Axis Direction

The determination of tooling axis direction for each component. The finding of the tool axis of each component by inspection and bisecting mentioned is the initial challenge. Some component like the armrest contains a side core axis to maintain the draft angle.

Dog House Positioning

The dog house on the main component needs to be positioned and drafted according to the main tool axis and side core axis. The dog house should maintain a minimum distance from side walls boundaries and attachment features like other doge houses and heat stakes

Heat Stake Position and quantity.

The position of heat stakes according to the master section and additional ones were challenging since they need to be drafted and positioned accordingly. By reducing the number of attachment features the quantity of material and complexity can be reduced drastically.

Minimizing The material quantity

The component is to be designed in such a way that the material quantity should be minimized. The goal can be by providing flanged only at the necessary place and maintaining the length of flanges. Minimizing the number of heat stakes and dog hose is another method to minimize material usage.

Attachments

Push pin clips are provided on the main component for attachments, the heat stakes are used to attach the sub-elements to the main part.

Plastic Model

Arm Rest

Map Pocket

Lower Substrate

Armrest Cushion

Draft Analysis

The draft Analysis is contacted to make sure that all parts of the component maintain a minimum draft angle with the tool axis.

The tool axis is founded on the visual inspection and bisecting method. Each part is manufactured separately, thus the toll axis is different for each of them. Some of the parts may contain multiple tool axis depending on their structure.

Lower Substrate