Week 11 - Final project
AIM – to design a door panel of an automotive using CATIA V5.
OBJECTIVES –
- To create an assembly and organize different surfaces of the given class A surface into different parts of the door trim panel. To create a tooling axis and perform a draft analysis on the class A surface of each part.
- To create class B, class c, surface and close surface for each part.
- To perform draft analysis on the close body of each part.
- To create engineering features (heat stakes, locators, dog house) to join the parts of the door trim panel together.
- To assemble push pine to the door panel
THEORY -
A door panel, also known as a door card, is an insert that covers the interior components of a vehicle’s door. Modern cars often have door cards that are constructed of plastic and incorporate other decorative elements, with injection molding being the most common method. Other features that add to the vehicle’s aesthetic, functionality, and ergonomics are usually included in the door panel. Armrests, s witches, or other control for the windows and locking mechanism, convenience lights, speakers, storage compartments, and other features are examples of this..
MAIN CONTENT –
Class A surface of a door panel received from the styling team. In the automotive industry dedicated team is allocated to develop class A surface using sketches followed by ideation. Class a surface is the first input given the plastic designer.
- CLASS A SURFACE OF A DOOR PANEL
- Front side
- Back side
- CREATION OF AN ASSEMBLY
Door panel class a surface has the following parts –
Door arm rest
Lower subset
Map pocket
Bottle holder
- Door arm rest
- Creation of tooling axis
The line has been created using the line command. The point-direction option is used to create the main tooling axis in the z-direction.
- Creation of class B surface
Class B surface has been created by offsetting of class A surface. Offsetting has been done using the command. Class A surface is offset with a 2.5mm distance. Surfaces that were not offsetting were formed using the multisection command.
- Creation of class C surface
Using the multiple extract commands, boundaries of class A surface were extracted. Class C surface joins class A and B surfaces. It is created using sweep command were extracted boundary, class-A surface, angle value, and length of the sweep. Due to surface irregularities, it was not possible to create a single sweep.
- Creation of close surface
Class A and class C surface were joined together.
The join of class A and class C surface is trimmed with class b surface to create a closed surface. While performing trim operation errors were coming as a proper intersection was not happening. Hence with the help of extrapolating command class B surface was extrapolated and finally trimmed.
- LOWER SUBSTRATE
- CLASS A SURFACE
Extract input surface
- Creating of tooling axis
The line has been created using the line command. The point-direction option is used to create the main tooling axis in the y-direction.
- Creation of class B surface
Class B surface has been created by offsetting of class A surface. Offsetting has been done using the offsetting command. Class A surface is offset with a 2.5mm distance.
- Creation of class C surface
Using the multiple extract commands, boundaries of class A surface were extracted. Class C surface joins class A and class B surfaces. It is created using the sweep command. Input for the sweep command. Inputs for the sweep command were extract boundary, class-A surface, angle and length of the sweep.
- Creation of close surface
Class A and class C surface were joined together.
The join of class A and class c surface is trimmed with class B surface to create a closed surface.
Above close surface is converted into the close body using the close surface command from the part design workbench.
- OUTER MAP POCKET
Creating class, A surface
Extract input surface
- Creating of tooling axis
The line has been created using the line command. The point-direction option is used to create the main tooling axis in the z-direction.
- Creation of class B surface
Class B surface has been created by offsetting of class A surface. Offsetting has been done using the offset command. Class A surface is offset with a 2.5mm distance. Surface that were not offsetting were formed using the multi section command.
- Creation of class C surface
Using the multiple extract commands, boundaries of class A surface were extracted. Class C surface joins class A and class B surface. It is crated using the sweep command. Input for the sweep command were extracted boundary, class-A surface, angle value, and length of the sweep.
- Creation of close surface
Class A and B class C surface were joined together.
Above close surface is converted into the close surface command from part design workbench.
4. INNER map pocket
Creating class, A surface
Extract input surface
- Creation of tooling axis
The line has been created using the line command. The point-direction option is used to create the main tooling axis in the y-direction.
- Creation of class B surface
Class B surface has been created by offsetting of class A surface. Offsetting has been done using the offset command. Class A surface of offset with a 2.5mm distance.
- Creation of class C surface
Using the multiple extract commands, boundaries of class A surface were extracted. Class C surface joins class A and class B surface. It is crated using the sweep command. Input for the sweep command were extracted boundary, class-A surface, angle value, and length of the sweep.
Creation of close surface
Class A and class C surface were joined together.
The join of class A and class C surface is trimmed with class B surface to create a closed surface.
Above class A surface is convert into the close body using the close surface sommand from part design workbench.
FLANGES - Flanges are the elements that are needed to join different component together. So, here I have to make flanges on the door armrest and the map pocket. Following the master section, given as the input basically the measurements and location of the flange. I have created the flange on the outer map pocket. For creating the flanges, I have taken extraction of the curve and made a point on that curve then created one plane on that point followed by creating a sketch on that plane taking the point created as the origin. The sketch is shown below.
After creating the flanges, I have created the dog house.
Dog house: - dog house is an engineering feature used in the plastic design. Dog house use as supporting features. Sometime other engineering features like snaps; locators, etc. are mounted on them to increase their strength. Dog house are subjected to draft analysis to prevent breakage of the component during ejection from the mold cavity. Dog house and other engineering components are built on B-surface.
Here the dog house is required for lower substrate only. So, for crating the dog house l has extracted the base surface and sketched on it. The sketch is shown below.
Then I have swept the above sketch along the tooling axis of lower substrate giving 1.5 degrees of the draft. The sweep is shown below.
Then I have closed the surface on the top. After closing the surface, I have used the thick surface command to make a solid body giving 2mm thickness. The thick surface is shown below
For this purpose, I have just offset the base of the lower substrate to a height of 4mm the value could be anything between 3-6mm and then I have extracted the inside portion of the dog house. The offset and extraction of surfaces are shown below
Then I have extracted the inside portion that extracted and trimmed it with the base which the base which saran offset of 4mm the show.
Push pine: - push pins are used for joining one component to another. These are basically attached to the dog house for creating the push pine I have taken the following reference basically the measurements.
Then I have made the cut out on the dog house for inserting the pin. For the cut out I have made one sketch on the top surface of the dog house and extruded it. The extruded is shown below:
ASSEMBLY OF PUSH PINS
Pushpin was placed on the dog house. Total three push pin were used.
Following mates are used to fixing the pish pine to the dog house.
Then I have used the copy and paste special option and translated the dog house along with a push pin to different location on the lower substrate in which I want the dog house. So basically, I have created point on the lower subtract and used the point translation. After doing the translation I have just added all the dog houses to the lower substrate. The result is shown below:
HEAT STAKES AND RIBS
The use of heat stakes is to attach two plastic components permanently. A total of 12 heat stakes were placed at different locations on the lower substrate. One heat has been created onto the door armrest part which will be attached to the upper substrate. Following the master section, the outer diameter of the heat stake is 7.5mm and the inner diameter is 4.5mm. necessary slots are made onto other parts where heat stakes will attach together. Draft of 0.5 degrees has been given to all the heat stakes. All the heat stakes have ribs attached to them. All the ribs have 1mm thickness and 0.5 degree of the draft. The length of the ribs is 14 x 14 mm.
Heat staking also known as thermoplastic staking is the process of joining two dissimilar materials together. In heat staking, we used local heating and cooling to raise the temperature of plastic components and allow plastic reforming to be carried out. This reforming can be used in a wide variety of applications.
The Tree Structure
CONCLUSION
The door panel has been successfully designed by following OME standards using in automotive industry. All the attachment features are properly placed at different locations he designed part meets all the designed objectives.