Challenge

Week 11 - Final project

AAkshay Bhaskar V8 Dec 2022

CATIA

Final project

Door Trim Panel

Aim : To create a CAD model of a side door trim panel from given class A surface .

Objective:

a) Creation of side door trim panle from given class A surface . Apply thickness to it and use attachment features .

b) Creation of flanges and heat stakes from given master sections .

c) Creation of dog house and various attachment features using industry standards .

d) Performing draft analysis and ensuring the features and surfaces clear it .

Introduction :

The ten stages in automotive product life cycle developement are listed below .

1)Concept sketch

2) Styling class A

3)Feasilbility check

4)Concept validation

5)New product design

6)Product developement

7) Prototyping

8)Design validation

9)Pilot production

10)Mass production

From the above stages , it isin stage 5 that new product is developed and validated from class A surface . The objective is to design class B and class C surface from given class A surface and create a solid body from it using softwares like CATIA V5, solidworks or solidedge taking into consideration the draft analysis which makes the component suitable for production using injection molding process .

Given below is the procedure to create a new plastic component from given class A surface .

1) Creation of tooling axis

2) Creation of class b surface

3) Creation of class C surface

4) Creation of closed body

5) Draft Analysis .

Draft analysis is done to ensure that the designed part is manufacturable based on the draft conditions applied. It is done to ensure the proper ejection of the component from dies(for metals) or molds(for plastics). The basic idea is to ensure that the tooling axis has to be created in such a wat that it has no parallel surface profiles of the component so that the ejection of the components can be ensured . Tooling axis is the axis along which cavity and core are closed and opened .

The main components of interior door panel of a car consists of the following parts .

1) Arm rest

2) Map pocket (Consists of upper and lower part)

3) Upper substrate (Not given in the current model)

4) Lower substrate .

Given class A surface

Rear side of the class A with master section

ARM REST

Creation of Tooling axis for Arm Rest

Step 1: Insert a geometrical set . Extract the base surface and create a point at its center using point on surface option from point tool. Look for suitable axis to create a tooling axis so that all faces clear tooling .

Step 2: Create an axis system without current option ticked at the above point. Create a position sketch with zy plane from axis system and above point as reference point.

Step 3: Use intersect 3d objects option from project tool to create 2 lines by selecting a suitable plane(zy). Now create 2 lines which coincide with lines on both sides of the projection point . Create a line using bisect option .Allign the line in required axis direction.This is our Y tooling axis .

Step 4: To create tooling axis about x direction, create a position sketch with xz plane as reference plane and projection point as the first point we created . Use cut section tool and create an intersection using projection tool . Now create a line that coincides with this line .

Step 5 : Draw a line from origin in horizontal direction and create and angle constraint of 5 degrees. Use bisect option to create a line between that above lines . This is out X tooling axis .

Step 6 : Create a new line using bisect option between X tooling and Y tooling line . this is our required Tooling Axis , Name this as tooling axis and publish it .

Creation of B Surface:

Step 1: Use offset tool with a distance value of 2.5mm to create offset of class A surface .

Step 2: After offsetting , extrapolate tool was used to extend all the edges of this surface . This is done to ensure that the parting line comes at B surface .

Step 3: In areas where extrapolate was not possible (Fillet or cusped surfaces) multisection surface option was used .

Step 4: Join all the extrapolated surface and multi section surfaces to obtain a single surface .

Creation of Class C surface

Procedure for creation of class C surface for Upper map pocket

Step 1: Use sweep command to create a new surface an an angle with respect to a surface . This angle is dependant on draft angle for free edges and ususally 90 degree for mating surfaces .

Step 2: In areas where sweep is not possible , use Multi section surface to create a new surface .

Step 3: Join all surfaces to obtain C surface.

Closed Body:

Parting line:

Draft Analysis :

Procedure to check Draft analysis for Lower substrate .

1)Once the tooling axis is created , publish it and the component using Publication from tool option .

2)Insert Feature draft analysis option from insert tool bar

3) Change the view option to customize view parameters and click om material option under shading .

4) Now click on the axis option from Draft analysis tools , allign it with tooling axis and click on lock option to lock it .

5) Change draft angle value to 3 degree . Click on quick analysis mode to display feature according to given color scale . Check from all views to ensure the draft analysis is cleared . Click ok to complete the Draft analysis mode.

Lower Substract

Creation of Tooling axis

Class B creation

Class C creation

Closed Body:

Parting Line:

Draft analysis:

MAP POCKET

Tooling axis creation

B Surface Creatoion

Class C creation

Closed Body:

Parting Line

Draft Analysis:

BOTTLE HOLDER

Tooling Axis creatiion

B Surface creation

C Surface creation

Closed body:

Parting line:

Draft Analysis:

Attachment of flanges using given master sections.

Procedure to create flanges and heat stakes for Arm rest part 2 from given master sections

Step 1: Use multiple extract to obtain required guide curve and sweep profile for flange top surface .

Step 2 : Use sweep option to create a surface from below obtained multiple extracts .

Step 3 : Use extrapolate to extend the surface according to master section and create a solid body in a new body. Create holes and flat surfaces for heat stake .

Step 4:Heat stake was created from padding a sketch created from a point obtained from master section.

Step 5: Stake support was created using padding the multiple extract from master section and thickening it .

Procedure to create dog house on lower substrate

Step 1: Create a point on required location and a plane from it . Create a sketch with base sketch for dog house

Step 2: Use sweep tool to create a surface using this profile and draft direction at a draft angle of 1.5 degrees .

Step 3: Use extrapolate and extrude option to create required surfaces and use trim and split to obtain the outer body of dog house .

Step 4: Create a new body and name it as dog house 1 . Use thick surface option to create a solid of required thickness .

Step 5: Translate the dog house to required height using translate option and use thick coomand to extend the base surface to intersect the lower substrate.

Step 6: Extract the inner base edge and create a surface to get the required base profile . Use thick surface to create a solid and use boolean operation to remove it from the base of dog house.

Step 7 :To create top profile for attachment of push pins , create a stech , extrude it and split it from the solid using split option

Step 8: To create a base for push pins to rest , create another sketch extrude and off set it . Create solids feom it using thick surface option .

Use boolean operation union trim to obtain required design.