Week 11 - Final project

AUTOMOTIVE PLASTIC DESIGN USING CATIA V5

FINAL PROJECT - DOOR TRIM DESIGN
SUBMITTED BT AKASH .D.PATIL

• THE INPUT GIVEN IN THE DOOR TRIM ASSEMBLY PROJECT ARE THE CLASS A SURFACE OF THE DIFFERENT PARTS.

THE ASSEMBLY CONSIST OF 4 PARTS:

-DOOR ARM REST

-LOWER SUBSTRATE

-MAP POCKET

-MAP POCKET WITH BOTTLE HOLDER.

• THE PHOTOS BELOW DESCRIBE ALL PARTS IN COMPONENTS IN ASSEMBLY.

• LOWER SUBSTRATE

THE MODEL OF COMPLETED LOWER SUBSTRATES WITH ALL ENGG. FEATURES AS FOLLOWS:

• THE INPUT FOR THE LOWER SUBSTRATE GIVEN IS CLASS A SURFACE .
• THE DIFFERENT ENNG FEATURES ON B SIDEON LOWER SUBSTRATE ARE:

-3 DOG HOUSES

-13 HEAT STAKES

(-SET 1 HEAT STAKES :FOR ASSEMBLY WITH DOOR ARM REST

-SET 2 HEAT STAKES:FOR ASSEMBLY WITH MAP POCKET

-SET 3 HEAT STAKES:FOR ASSEMBLY WITH MAP POCKET BOTTLE HOLDER)

DETAIL PICTORIAL REPRESENTATION OF B SIDE FEATURES:

MAIN TOOLING AXIS FOR LOWER SUBSTRATE:

• THE MAIN TOOLING AXIS IS HIGHLIGHTED IN BROWN COLOUR IN MODEL.
• BELOW PIC SHOWS DRAFT ANALYSIS FOR CLOSED SOLID ONLY WITH DRAFT ANGLE LIMIT 3 DEGREE (EXCLUDED B SIDE FEATURES)

• THE BELOW PICTURE SHOWS DRAFT ANALYSIS FOR B SIDE FEATURES[ HEAT STAKES AND DOG HOUSE] WITH REPECT TO MAIN TOOLING AXIS WITH DRAFT ANGLE 0.5 DEGREE.

• LIFTER TOOLING AXIS FOR DOG HOUSES:

THE 3 DOG HOUSES ARE PROVIDED WITH SEPARATE LIFTER AXIS, HIGHLIGHTED IN YELLOW IN MODEL

DRAFT ANALYSIS FOR DOG HOUSE 1

• WITH RESPECT TO MAIN TOOLING AXIS

DRAFT ANALYSIS WITH RESPECT TO LIFTER AXIS :

• THE DIMENSION OF DOG HOUSE TAKEN ARE : 30X30X55 mm (L*B*H)
• THE DRAFT DRAFT FOR OUTER SIDE 1.5 DEGREE
• DRAFT FOR INNER SIDER IS 0.5 DEGREE
• RIB THICKNESS=2mmWHICH IS 0.5*WALL THICKNESS
• CORING FOR 6 MM IS DONE FROM BASE OF LOWER SUBSTRATE TO AVOID SINK MARKS

LIFTER DESIGN CONSIDERATION FOR DIG HOUSE:

IT IS IMPORTANT CONSIDERATION WHILE DESIGNING THE DOG HOUSE THA THE LIFTER HAS ENOUGH SPACE FROM FRONT SIDE OF DOG FOR REMOVAL PURPOSE.

SO, APPROXIMATELY 2W SPACE SHOULD BE AVAILABLE INFRONT OF DOG HOUSE , WHICH I TAKEN IN CONSIDERATION IN THIS DESIGN.

THE PIC REPRESENSTS THE FOLLOWING :

• DOOR ARM REST

THE FINAL MODEL OF DOOR ARM REST SHOWN BELOW:

• THE ENGG FEATURES ON B SIDE OF DOOR ARM REST ARE 4 FLANGES.
• THE THICKNESS OF FKANGES IS 2.5mm (EQUAL TO WALL THICKNESS)
• THE DIMESNION OF ALNGE ARE MAINTAINED AS 30*30mm.
• ALSO DISTANCE BETWEEN 2 FLANGED IS MAINTAINED AS 45mm for heat staking process.

DRAFT ANALYSIS FOR DOOR ARM REST WITH RESPECT TO MAIN TOOLING AXIS: (3 DEGREE)

SOLUTION FOR MANUFACTURING:
THE SMALLER PART IS NOT CLEARING IN THE MAIN TOOLING AXIS , SO HERE WE HAVE TO MANUFACTURE THIS PART IN 2 SPLITS, AS THE PART WILLL BE COVERED WITH LEATHER , IT WONT BE VISIBLE AND ASTHETIC PROBLEM OF SPLITTING THE PART WONT EXSIST.

DRAFT ANALYSIS FOR FLANGES: (0.5DEGREE)

• MAP POCKET:

THE FINAL MAP POCKET MODEL WITH ENGG B SIDE FEATURES IS AS FOLLOWS:

THE B SIDE FEATURES CONSIST OF

-3 HEAT STAKES (TO ASM WITH BOTTLE HOLDER)

-2 SET OF FLANGES (TO ASM WITH LOWER SUBSTRATE)

• MAIN TOOLING AXIS FOR MAP POCKET: (IN YELLOW)

DRAFT ANALYSIS FOR CLOSED SURFACE WITHOOUT B SIDE FEATURE: (3 DEGREE)

DRAFT ANALYSIS FOR CLOSED BODY AND HEAT STAKES (0.5DEGREES)

DIMENSION AND DRAFT MAINTAINED FOR HEAT STAKES:

• RIB THICKNESS=1.25MM
• RIB L*B=16*16MM
• HEAT STAKE CYLINDER DIA= 7.5MM
• HEAT STAKE INNER CYLINDER DIA = 4.5MM
• DRAFT GIVEN 0.5 DEGREES

• MAP POCKET WITH BOTTLE HOLDER:

THE FINAL MODEL IS AS FOLLOWS :

• THE B SIDE FEATURES MADE IN THIS MODEL ARE :

-3 SET OF FLANGES

(-1 SET TO ASM WITH MAP POCKET

-2 SETS TO ASM WITH LOWER SUBSTRATE )

MAIN TOOLING AXIS FOR BOTTLE HOLDER MAP POCKET:

THE AXIS HIGHLIGHTED IN BLACK IS THE MAIN TOOLING AXIS FOR THIS COMPONENT.

DRAFT ANALYSIS FOR CLOSED SOLID (EXCLUDING B FEATURES FOR 3 DEGREES)

B SIDE ENGG. FEATURES- FLANGES

TO STRENGTHEN TH FLANGES , RIBS HAVE BEEN DESIGNED TO MAKE FLANGES RIGID , AS SHOWN BELOW.

RIB THICKNESS =1.2mm

FLANGE THICKNESS = 2.5mm

HOLE DIA IN FLANGE = 8.5mm