Week 11 - Final project
AIM:-
- CLASS A surfaces of the DOOR ARM REST, MAP POCKET, BOTTLE HOLDER and LOWER SUBSTRATE.
- Master section for the attachment features.
- Push clips for the assembly.
OBJECTIVES:
- Analysing the class A and performing necessary modification to obtain the modified class A.
- Creating the tooling axis for all the components .
- Performing draft analysis of class A surface.
- Creating the class B surface with the help of surface workbench.
- Creating the class C surface with necessary draft.
- Trimmimg the CLASS A,B AND C Surface for obtaining the final trim for all the components.
- Creating the closed body for all the components.
- Creating the attachments on the LOWER SUBSTRATE for assembly like DOG HOUSE, HEAT STAKES, AND RIBS.
- Creating the flanges on the other three components for the assembly purpose.
- Creating the Side core tolling axis.
- Performing the vigrous draft analysis and make sure all parts are clearing with positive and required draft.
- Assembly of the push pins over the dog house in assembly workbench.
- Final submission.
ANALYSING THE PROJECT:
- DOOR TRIM DEVELOPMENT IN CATIA V5.
#About the software: CATIA V5
CATIA is the world’s engineering and design leading software for product 3D CAD design excellence.It is used to design, simulate, analyze, and manufacture products in a variety of industries including aerospace, automotive, consumer goods, and industrial machinery, just to name a few. It addresses all manufacturing organizations, from OEMs through their supply chains, to small independent producers.
If you stop and take a look around, CATIA is everywhere. CATIA is in the plane that just flew over, the car that just went silently by, the phone you just answered, and the bottle of water that you just finished.
Here, we have used the PART , SHAPE(GENERATIVE SHAPE DESIGN ) AND PRODUCT/ ASSEMBLY WORKBENCH.
#DOOR TRIM OF THE AUTOMOBILE:
- Door panels serve as an interface between the interior of the car and the inner workings of the door, and between vehicle occupants and the door.
- They are expected to meet a variety of design specifications regarding safety, aesthetics, and functionality. In addition, they are expected to continue the material theme of the dashboard and pillars while concealing intricate electrical and mechanical components for operating locks, windows, and other features.
- The door panel has evolved from a simple two-part system of latch and simple winding mechanism to a more sophisticated enclosure. Doors currently have an inner full-width panel consisting of electronic windows, central locking system, and speakers.
- These panels typically consist of a foamed core covered with either textiles or plastics.
- Plastics is the core and soul of the door trim interior, one must have knowlege about the plastic being used and its cost associated with the molding and manufacturing.
1)CLASS A SURFACE :
- Class-A (or 'Strak') is a term used in specifically in automotive design. It describes the final production surface data for the aesthetic parts of the car.
- The term 'Class A' is often misunderstood, but it's generally seen as the 'Holy Grail' of surface modelling. This is because as it achieves the highest surface quality levels, and it demands a high level of automotive design knowledge as well as surface modelling skills.
- Class A represents the 'craftwork' end of the design process. Creating the main surface shapes to describe the vehicle is the primary design activity. But the painstaking, detailed craftsmanship of perfecting those surfaces, designing flanges and panel gaps is what guarantees that a beautiful design turns into a beautiful manufactured product.
- Here we have four class A surfaces as inputs:
a)LOWER SUBSTRATE.
b)DOOR ARM REST.
c)BOTTLE HOLDER .
d)MAP POCKET.
2)TOOLING AXIS CREATION :
- Tooling axis plays important role in plastic product manufacturing and designing, this axis decides the direction in which mould is going to work while production of the component.
- The main focus while deciding the tooling axis is clearing the component in the moulding in the same axis with the minimum use of the side core for producing the component, the side core usually adds up to the cost of the component.
- For the particular component X,Y and Z can be the possible direction for the tooling axis.
- You must specify the axis system by creating the point on the surface.
- With the help of the intersect in the YZ plane create the tooling axis in YZ plane .
- With the help of the intersect in the ZX plane create the tooling axis in ZX plane.
- The last step is to bisect the two tooling axis to obtain the main tooling axis of the class A surface.
- LOWER SUBSTRATE
- DOOR ARM REST
- MAP POCKET
- BOTTLE HOLDER
3)OVERALL CLASS A SURFACES
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4)CREATING THE CLASS B SURFACE:
- Class B surface is the surface which is created with the help of class A surface as the reference.
- The the class B surface is the surface where all the necessary attachments and supports of the component is made .
- The main parts without the edge fillets are extracted and untrimmed and then they are extrapolated for better view.
- The extrapolated parts are then made offset with reference to the class A with the thickness of the component, here thickness of the component for base bracket is 2.5 mm.
- The offset surfaces are then trimmed to attain the class B surface.
- You can even directly offset the class A for obtaining the class B surface.
- The final class B surface must have the edge fillets similar to the class A and fillets must be given properly with a thought of maintaining same thickness throughout avoiding the flow line defects.
a)LOWER SUBSTRATE.
b)DOOR ARM REST.
c)BOTTLE HOLDER.
d)MAP POCKET
5)CREATION OF CLASS C SURFACE AND TRIM :
- The class C surface is the surface which is created to provide thickness to the class A surface with the help of class B surface.
- The class C surface is the middle portion of the class A and class B surfaces.
- The class C is created with the help of the sweep command in surface workbench.
- The class A surface's boundary is taken as profile (guide curve) and then tooling axis created is taken as direction of the sweep in subtype draft direction
- The draft angle for the sweep is 3 degrees.
- The holes are created using the same axis and draft angle.
- The attained sweep is joined with class A surface to obtain the class C surface.
- The final trim is obtained by trimming the class B with the class C surface.
- The final check to ensure the proper clossness of surface with the boundary command .
LOWER SUBSTRATE
DOOR ARM REST
BOTTLE HOLDER
MAP POCKET
6)CREATING THE CLOSED BODY AND ASSIGNING IT AS MAIN BODY
- Move to the part window and with the help of surface based feature close the surface to get the closed part body.
- Follow this for all the components.
7)CREATING THE ATTACHMENT FEATURES FOLLOWING THE MASTER SECTION.
#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 in order to fix the other.
- Heat Staking makes it easy to bond metal to plastic and is commonly used in high volume/low cost applications such as automotive, IT and consumer appliances.
- Similar and dissimilar materials may be joined: metal to metal, plastic to plastic, metal to plastic
- Accurate control operating within a small process window
- Local heating resulting in no damage to surrounding materials
- Processing of glass-filled materials
- No mechanical vibration
- Many heat-stake shapes possible through custom designed tools.
#RIBS
- The ribs provide economical stiffness and strength to the part without increasing the overall thickness of the part.
- The ribs are used as locating and arresting in the assembly as locators.
- Proper allignment in mating parts, slot and rib pair is long lasting other than screw pair which loosen up with time.
- Acting as stops or guide for mating the tilted headlamps.
- Rib designs includes.
- thickness, quantity, height , manufacturibility and location.
#DOG HOUSE
- Dog house is the attachment feature which helps you to assemble things at certain heights and also resolve the plastic defects.
- There are plenty dog house design which can be used for assembly purpose but we will be using the one provided to ous by the resources.
- The master section or the enginnering drawing must be followed for creating the dog house.
Tree layout
Draft Analysis:-
MAP POCKET:-
BOTTLE HOLDER:-
LOWER SUBSTRATE:-
MAP POCKET:-
Conclusion :- Hence completed the following challenge of the Door Trim and its Master section for the attachment features and Push clips for the assembly.