Week 11 - Final project

INTRODUCTION

The door trim panel of a car is the interior parts of the door which contains the most controls and decorative parts, the main components of interior door panel of a car consist of the following parts

• Arm rest
• Map pocket
• Upper substrate
• Door lower substrate

METHODOLOGY

The procedure followed for creating the Interior Door trim panel is the same as followed in the OEMs and Tier-1 companies. First, the Class A surface is divided into sub-parts and the geometrical sets are rearranged. Then tooling axis, improvement of Class A surface, Class B surface, Class C surface, and B-side attachments are created. After this Draft analysis is performed to check the manufacturing feasibility.

TOOLING AXIS CREATION

Tooling axis creation is the first step , here in this project the tooling axis is created using bisecting method and normal to surface method. The tooling axis or tooling directiuon is the direction in which the mold opens.By using this tooling axis as referance we are giving draft for each part, and we draft analysis are also performing using the tooling axis as reference, here we want to create tooling axis for every part seperately.

ARM REST

LOWER SUBSTRATE

UPPER SUBSTRATE

MAP POCKET

DRAFT ANALYSIS

Draftf analysis is done to check whether that the designed part is manufacturable or not based on its draft condition as per industrial standards . As per the industrial standards the nominal draft for plastic components are given as 3 deg. Draft angles are given to the part to ensure the proper ejection of the component from the dies or molds. The cavity and core are opened in the direction of tooling axis. Draft analysis are done at two stages mainly in a part design process, first analysis is done on class A surface before the design starts and next is after the creation of final body by giving thickness to close body.The procedure for the draft analysis are the following

• Once the tooling direction is created we can do draft analysis .
• At first change the view mode to customized view and select material mode. After that open the draft analysis tool.
• Click on the compass and place the compass along with the tooling axis and then click on the surface to be analysed ,then the catia shows the draft analysis of the surface ,we can select the required draft angle as per our need here select the draft of 3 deg as per industrial standards for the main part body and select currosponding value for the draft analysis of the attachment features
• we can identify the draft of the surface by various colour ranges.

ARM REST

LOWER SUBSTRATE

UPPER SUBSTRATE

MAP POCKET

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 : 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.

• 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

• 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.

ARM REST

LOWER SUBSTRATE

UPPER SUBSTRATE

MAP POCKET

FINAL PRODUCT

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.