Week 11 - Final project

Automotive Interior Door Trim Panel Design With Master Section

Aim:

The project aims to design and develop the Automotive Interior Door Trim Panel with engineering features like Haet Stakes, Push Pin, and a Dog house. Also, perform a draft analysis to check the manufacturing feasibility.

Objective:

• To create thickened parts using the master section for reference.
• To create the mounting features as per design guidelines in the industry and with master sections.
• Apply material details :
• To perform Draft analysis & Tooling analysis

Given Class A Surfaces With Master Section:

To design the component first we need Class A Surface, if we have Class A Surface means we can create the tooling axis and do further design.

Arm Rest Class A Surface:

Lower Substrate Class A Surface:

Upper Substrate Class A Surface:

Map Pocket Class A Surface:

Class A Surface Inspection:

We have checked the class A surface whether it is suitable for class B & C surface creation or not by using disassembly, boundary, and other different methods.

Arm Rest Class A Surface Correction:

Here, the given class A surface has some issues and we have to correct that after getting a clear report from the class A designer.

Corrected Class A Surface of Arm Rest:

Tooling Axis:

The tooling axis is very important to design a product. It is nothing but the direction of the molds open and close and whether it moves in the x, y, or z direction. First, we have to decide which direction is probably suitable for the particular product. Once we get the Cass A Surface, we can check the surface and able to create the tooling direction.

Here we have to create a separate tooling axis for all four parts and a side core tooling axis for the dog house.

1. Arm Rest Main Tooling Axis:

Procedure to Create the Tooling Axis:

• First, we have to create a point on the flat surface.
• Once we created the point, we have to create a sketch using the zx plane and the point.
• Then using intersect 3D element command we have to draw the lines which might create problems.
• After creating the two lines which might create a problem, then draw a bisecting line using the two lines that we have drawn from the intersect 3D element.
• Here we used Bisecting Method to create the Tooling axis.

Side Core Tooling Axis to clear the Engineering Features:

From the master section, we can create the side core tooling axis for the engineering features.

2. Lower Substrate Main Tooling Axis:

Procedure to Create the Tooling Axis:

• First, we have to create a point on the surface.
• We have to find the suitable direction by simply seeing the object from the x,y, and z directions. If the object is fully visible from one of the directions then that is the line direction or tooling axis direction.
• Here, the direction is the y direction. We have to create a line using the point and the y direction.
• This line will be our tooling axis if it clears the draft analysis.

Side Core Tooling Axis to clear the Dog House:

• After creating the main tooling axis we can create the side core tooling axis by using the point-direction line with the help of the point and x direction.

3. Upper Substrate Main Tooling Axis:

Procedure to Create the Tooling Axis:

Here also we are using the same method that we used in the Lower substrate.

• First, we have to create a point on the surface.
• We have to find the suitable direction by simply seeing the object from the x,y, and z directions. If the object is fully visible from one of the directions then that is the line direction or tooling axis direction.
• Here, the direction is the y direction. We have to create a line using the point and the y direction.
• This line will be our tooling axis if it clears the draft analysis.

4. Map Pocket Main Tooling Axis:

Here also we are using the same method that we used in the Lower substrate and Upper substrate.

• First, we have to create a point on the surface.
• We have to find the suitable direction by simply seeing the object from the x,y, and z directions. If the object is fully visible from one of the directions then that is the line direction or tooling axis direction.
• Here, the direction is the y direction. We have to create a line using the point and the y direction.
• This line will be our tooling axis if it clears the draft analysis.

Draft Analysis:

Draft: Draft is used to remove the component from the core and cavity. It will reduce the wear in components and molds so the life of the core and cavity will increase.

Draft Analysis: The Draft Analysis allows the user to easily analyze a part for a proper draft angle. A Draft Angle describes the amount of taper for molded or cast parts perpendicular to the parting line.

The minimum draft angle ranges between 0.5 o 3 degrees. Mostly 3-degree angle is widely used to make many components.

Class A Surface Draft Analysis:

Procedure to do Draft Analysis:

• Once we created the tooling axis means we can do a draft analysis. First, we have to switch the view mode to shading with the material.
• After switching to shading with material mode we can now click the draft analysis tool. Then we have to place the compass on the tooling axis by clicking and dragging the compass red dot.
• After placing the compass lock the direction and click the surface to do a draft analysis.

1. Arm Rest Class A Surface Draft Analysis:

• From the above image we can see that the green area has a draft angle above 3 degrees.
• If the color is red means negative or below 0 degrees.
• Here we can see the red color on the surface which shows that the red area will not clear the main tooling axis. And it will not be clear by any other axis so we have to give a clear report to the class A surface designer.
• If there is any blue color surface means the draft angle ranges between 0 to 3 degrees.
• We can change the color and angle value by clicking the color and values. But green, blue, and red are standard colors.

2. Lower Substrate Class A Surface Draft Analysis:

• From the above image we can see that the green area has a draft angle above 3 degrees.
• If the color is red means negative or below 0 degrees. Here there is no red or blue color surface is visible.
• If there is any blue color surface means the draft angle ranges between 0 to 3 degrees.
• We can change the color and angle value by clicking the color and values. But green, blue, and red are standard colors.

3. Upper Substrate Class A Surface Draft Analysis:

• From the above image we can see that the green area has a draft angle above 3 degrees.
• If the color is red means negative or below 0 degrees. Here there is no red or blue color surface is visible.
• If there is any blue color surface means the draft angle ranges between 0 to 3 degrees.
• We can change the color and angle value by clicking the color and values. But green, blue, and red are standard colors.

4. Map Pocket Class A Surface Draft Analysis:

• From the above image we can see that the green area has a draft angle above 3 degrees.
• If the color is blue means it ranges between 0 to 3 degrees.
• Here we can see the blue color on two side surfaces it shows that the blue area has a 0-degree draft angle. And it might not be clear by the tooling axis so we have to give a clear report to the class A surface designer.
• If there is any red color surface means the draft angle is below 0 degrees or negative.
• We can change the color and angle value by clicking the color and values. But green, blue, and red are standard colors.

Class B Surface Creation:

Class B Surface is the inner surface it can be created by using the class A surface by using several surface features.

Basic Features used in Class B Creation:

• Offset
• Extract
• Trim
• Extrapolate
• Radius
• Sweep
• Join
• Multisection
• Extrude etc.,

1. Arm Rest Class B Surface Creation:

As per the given master section, the given Class A surface is for the other leather so we have to offset the given class A to 2mm to create the inner class A surface that is Class B Surface_1.

Class B Surface_2 from Class B Surface_1

2. Lower Substrate Class B Surface Creation:

We can directly offset from the class A surface then we have to correct the missing area by using the commands that I have mentioned in the tree structure.

3. Upper Substrate Class B Surface Creation:

We can directly offset from the class A surface then we have to correct the missing area by using the commands that I have mentioned in the tree structure.

4. Map Pocket Class B Surface Creation:

We can directly offset from the class A surface to get the class B surface.

Class C Surface Creation:

The surface which is used to close the class A and class B surfaces are called the class C surface. Simply it gives thickness to the component. We can create the surface using the features mentioned in the below image or other features.

1. Arm Rest Class C Surface Creation:

Here, we can create the C surface using sweep with a reference surface and sweep with draft direction also we can use multi sections for twisted corners.

2. Lower Substrate Class C Surface Creation:

3. Upper Substrate Class C Surface Creation:

4. Map Pocket Class C Surface Creation:

Final Surface Creation:

After the joining of class A and B surfaces, we can trim it with the class B surface which we created.

1. Arm Rest Final Surface Creation:

Class A + Class C Surface:

Class A+B+C Surface:

After creating the final surface we have to ensure that the surface is fully closed by using the boundary command. If it shows an error, then there is no open boundary so we can decide that the final surface is closed.

2. Lower Substrate Final Surface Creation:

Class A + Class C Surface:

Class A+B+C Surface:

After creating the final surface we have to ensure that the surface is fully closed by using the boundary command. If it shows an error, then there is no open boundary so we can decide that the final surface is closed.

3. Upper Substrate Final Surface Creation:

Class A + Class C Surface:

Class A+B+C Surface:

After creating the final surface we have to ensure that the surface is fully closed by using the boundary command. If it shows an error, then there is no open boundary so we can decide that the final surface is closed.

4. Map Pocket Final Surface Creation:

Class A + Class C Surface:

Class A+B+C Surface:

After creating the final surface we have to ensure that the surface is fully closed by using the boundary command. If it shows an error, then there is no open boundary so we can decide that the final surface is closed.

Final Part With Engineering Features:

We created only surfaces but we need a solid part so after the creation of all surfaces we should close the surface from the part workbench.

1. Arm Rest Final Part:

As per the given Master Section, the Final Arm Rest part is made with engineering features like flanges and heat stakes.

Here, we can see that the features are made as per the given Master Section.

2. Lower Substrate Final Part:

As per the given Master Section, the Final Lower Substrate part is made with engineering features like flanges, heat stakes, a Dog House and Push pins.

3. Upper Substrate Final Part:

As per the given Master Section, the Final Upper Substrate part is made with attachment features like flanges.

4. Map Pocket Final Part:

As per the given Master Section, the Final Map Pocket part is made with attachment features like flanges.

Engineering Features:

Heat Stakes:

Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic. The process is to deform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part to fix the other.

Here, the Heat Stakes are created as per the given Master Sections.

Dog House Creation:

The dog house is an engineering feature used in the plastic trim design. Dog houses are used as supporting features. Sometimes other engineering features like snaps; locators, etc. are mounded on them to increase their strength.

Here, the Dog House is created as per the drawing.

Dog House Design Roles:

• Take the Thickness of the component to be 2.5 mm

• "C" is where the doghouse contacts the backside of the surface.

Push Pin Clip:

• It is used to attach to parts by pushing them together using the clip.
• It is usually placed on the Dog House to hold the clip firmly.

Final Part Draft Analysis With Engineering Features:

Procedure to do Draft Analysis:

• First we have to switch the view mode to shading with the material.
• After switching to shading with material mode we can now click the draft analysis tool.
• Then we have to place the compass on the tooling axis by clicking and dragging the compass red dot.
• After placing the compass lock the direction and click the surface to do a draft analysis.

1. Arm Rest Final Part Draft Analysis:

Main Tooling Axis:

• From the above image we can see that the green area has a draft angle above 3 degrees.
• If the color is red means negative or below 0 degrees.
• Here we can see the red color on the curved surfaces which shows that the red area will not clear the main tooling axis. And it will not be clear by any other axis so we have to give a clear report to the class A surface designer.
• If there is any blue color surface means the draft angle ranges between 0 to 3 degrees.
• We can change the color and angle value by clicking the color and values. But green, blue, and red are standard colors.

Side Core Tooling Axis:

• This axis is created for engineering features. From the above image, we can see that the green area has a draft angle above 3 degrees.
• If the color is red means negative or below 0 degrees.
• Here we can see the red color on the surface which shows that the red area will not clear the main tooling axis. And it will not be clear by any other axis so we have to give a clear report to the class A surface designer.
• The blue color surface indicates the draft angle ranges between 0 to 3 degrees.
• We can change the color and angle value by clicking the color and values. But green, blue, and red are standard colors.

2. Lower Substrate Final Part Draft Analysis:

• From the above image we can see that the plastic component is clearing the draft analysis so that it is possible to manufacture this part.
• The green area has more than a 3-degree angle so it is possible to eject the component from the mold without sticking to the mold.
• We can see a blue color area on the dog house faces which means the draft angle ranges between 0 to 3 degrees but the actual degree is 0.5 degrees we can check the individual spot degree by using analysis under the running point tool in the display of the draft tool.

Dog House Draft Analysis:

Main Tooling Axis:

• The green area has more than a 2.9-degree angle so so the main tooling axis will clear the draft analysis.
• We can see a blue color area on the dog house faces which means the draft angle ranges between 0 to 3 degrees but the actual degree is 0.5 degrees.
• We can check the individual spot degree by using analysis under the running point tool in the display of the draft tool.

Side Core Tooling Axis:

• The green area has more than a 2.9-degree angle so so the side core tooling axis will clear the draft analysis.
• We can see a blue color area on the dog house faces which means the draft angle ranges between 0 to 3 degrees but the actual degree is 0.5 degrees.
• We can check the individual spot degree by using analysis under the running point tool in the display of the draft tool.

3. Upper Substrate Final Part Draft Analysis:

• From the above image we can see that the plastic component is clearing the draft analysis so that it is possible to manufacture this part.
• The green area has more than a 2.9-degree angle so it is possible to eject the component from the mold without sticking to the mold.
• We can see a blue color area on the flange faces which means the draft angle ranges between 0 to 2.9 degrees but the actual degree is 0.5 degrees we can check the individual spot degree by using analysis under the running point tool in the display of the draft tool.

4. Map Pocket Final Part Draft Analysis:

• From the above image we can see that the plastic component is clearing the draft analysis so that it is possible to manufacture this part.
• The green area has more than a 2.9-degree angle so it is possible to eject the component from the mold without sticking to the mold.
• We can see a blue color area on the two faces which mean the draft angle ranges between 0 to 2.9 degree but the actual degree is 0 degree we have to make a report regarding this to inform the class A surface designer.
• We can check the individual spot degree by using analysis under the running point tool in the display of the draft tool.

Weight of the Components:

• Apply plastic material to all the components.
• Click Measure inertia to find the mass of the component.

1. Arm Rest Final Part Weight:

2. Lower Substrate Final Part Weight:

3. Upper Substrate Final Part Weight:

4. Map Pocket Final Part Weight:

Final Component Weight:

The Total Weight of the component is 1.313kg.

Different Views of the Component:

Conclusion:

Thus the design of the Automotive Interior Door Trim Panel with engineering features like Heat Stakes, Push Pin, and Dog house was created as per the given class A surface and Master Section by considering the design rules that were followed by Tier 1 companies and OEMs. Also, the draft analysis was performed for all the components and engineering features.