Week 11 - Final project
REPORT:
Input Files opened in Catia.
form the MASTER_SECTION_DEVELOPMENT_SEPERATED_MODEL.
In Assmbly workbench, this part is opened as existing part.
Then New Product is insertd, as RH_DOOR_ASSEMBLY1.
in this assemblt nee Parts are inserted for easch Surface in INput.
Named as
Arm Rest1., Body1, Body2, and Bin1.
each part is with respective surface geometry.
RH_DOOR_ASSEMBLY1 is now opend in new window.
Started working on each part, with Body1 at first.
Tooling axis created using line normal to surface option and performed draft analysis, major surface is clearing draft analysis except a cornar and fillet area.
Hence created anothe rtooling axis using biection method and performed Draft analysis once agin, but same area was not clearing draft analysis.
Hence started with the tooling Axis , created using bisecting method.
CLASS B SURFACE CREATION-
Input class A surface is offseted to 2.5mm.
It was perfectly offseted.
Extrapolated boundary of class B surface by 0.5 mm.
CLASS C SURFACE CREATION-
As class C sueface is Perpendicular to Tooling axis, Sweep Normal to surface selected for creation.
Complete C surface was not possible in a single sweep, hence it is co,[leted in parts. and joined to a single C surface.
Next Step Class A and Class C surfaces are joind and trimmed with extrapolated B surface to get a closed surface.
This closed body is cinverted to Part body.
Draft analysis performed for closed surface and part body also.
BODY2:
Tooling Axis 1
Tooling Axis 2-
Tooling Axis 3
Tooling Axis 4
Fianl Tooling Axis.
Final Tooling axis is one whiach is clearing maximum are in dreaft analysis. Though its not clearing complete surface. This tooling axis is final one.
and continuiong further work this as final tooling axis.
BIN-
Tooling Axis Creation -
Lin enormal to surfce i stoolimg axis.
Draft analysis is clear.
Class B creation -
Offset class A by 2.5 mm.
ARM REST1
Draft Analysis-
Class A surface-
2 Araas are not clearing draft analysis , tried to change tooling axis also. but same got same result.
hence continuiing with the same Tooling Axis. ans Same A surface.
Closed Surface
Closed Body-
Doghouse Creation
Map Pocket and Lower Subtrate need Dog houses.
1 Dog house for Map pocket
2 dog houses for lower subtrate.
Design CLaculations For Dog house-
Thickness DGH= T=2.5 mm
Height = 20 mm
MIn thickness at joint of B surface = C= 0.4 X 2.5 = 1 mm.
Height of C =H= between 3 to 6 mm .
Draft = 1.5 degree, outer walls. with Main tooling Axis
Draft = 0.5 degree. inner walls , with lifter axis.
Draft Analysis-Inner surfaces along slider axis.
Creation of Flanges From Master Section-
Two types of flanges are there. For arm rest side and Map Pocket side. They are created as per reference.
width of Flange is 30 mm. Distance between two consecutive flanges maintained minimum 50 mm.
Thickness is 2.5 mm.
NO master section provided for Bottle holder side, Hence created flat support for heaat stakes in this area.
Heat Stakes Creation-
From Master section, Heat stakes are created with OD 7.5 mm, and ID 4.5 mm.
Height is considered as required to cross lower subtrate.
Master Section was created as separate Part. hence I created all flanges, and Heat Stakes in thos Part and By usinf copy Paste Special, All the components Union Trimmed with respective parts.
Assembly-
Push Pin was provided as Input.
Need to assemble push pin with 3 dog houses. Using Coincidance constraint, the push pins and dog house connected.
About Material Selection:-
About Requirements-
Interior parts that contain the most controls and decorative parts.
It is necessary to balance gap between parts, as well as an overall sense of unity between the numerous parts.
Interior trim parts are extremely diverse. Each part has a certain level of functionality as well as aesthetic appeal.
As in current project, Right Hand side Door-
following properties are required
Good Surface finish
high dimensional stability
Good abrasion and strain resistnace
Rigidity
Impact Resistnace-
BOTTLE HOLDER-MAP POCKET-
Made of ABS plastic, ABS material is having all the qualities.
-
ARM REST-
An armrest should be made of very durable materials as it wear out the fastest.
Also it should provide comfortable support – Neither too hard such that, it may cause discomfort nor too soft, as it may provide poor hand stability.
Expanded polypropylene (EPP) is the best option, as it does not undergo permanent deformation and returns to its previous shape after the pressure has ceased.
Door Trim- Require
high Impact resistance.
high dimensional stability
Good abrasion and strain resistnace
Rigidity
Light weight
Generally ABS is used. But for more strength and impact resistance, foam is also composed with traditional material to reduce weight and achieve highe impact resistance.