Week 11 - Final project
DEVELOPMENT OF A DOOR TRIM PANEL
OBJECTIVE: The main objecctive of the project is to create a solid body by using closed surface command out of class-A surface by creating class-b and class-c surfaces.
ABSTRACT: First we need to make tooling axis for the class A surface in which direction the mold is going to open and close, then we need to do draft analysis for class A surface weather the component is ejected from the mold or not. Class B surface is obtained by offset of class A of the required thickness. Then we need to make class C by using sweep command from class A and then we need to join A and C then trim it with B surface. The closed surface body is odtained then we need to do draft analysis for closed surface weather the component manufacturable or not, then we need convert it into solid body the final output is obtained.
APPROACH:
Our basic approach to make a plastic model from class-A surface should be:
- Tooling axis for class A
- Draft analysis for classA
- Make B surface
- Make C surface
- Make it to closed surface
- Final Draft analysis
- Solid conversion
TOOLING AXIS : Tooling axis means the direction in which core and cavity open and close.Tool is nothing burt mold, tooling axis is created to know in which direction the mold open and close, parts drafts are given along this axis.
DRAFT ANALYSIS : Draft analysis is done to check weather the tooling axis and draft angle are correct or not and to find weather the component is manufactured and ejected or not. Draft Analysis is a tool in CATIA which identifies the zones which deviates from the specified values of angles along a defined draft direction using colour codes.
CLASS A SURFACE : Asurface is the aesthetic surface created by the class-A engineer. It is the visible aesthetic surface of any automotive component. class A surface is any of a set of freeform surfaces of high efficiency and quality.
CLASS B SURFACE : B surface is the offset of the class A surface. Class B surfaces are Engineering Surfaces which are invisible to the eyes or often on the back side of the Class A surfaces. It is mainly the thickness of the component or Class A.
CLASS C SURFACE : C surface is joining surface between A and C. Class C surfaces are connectors between Class A and B surfaces. This surface connects both A and B surfaces along the Tooling Axis. It contains the draft as per the design. Its is basically the thickened surface between both A and B surface.
MATERIAL SELECTION AND REASON FOR SELECTING THAT PARTICULAR MATERIAL :
Door trim panel Made of highest quality ACRYLONITRILE BUTADIENE STYRENE (ABS) or polypropelene materials.
REASON FOR CHOSSING MATERIAL:
- High rigidity.
- Good impact resistance, even at low temperatures.
- Good insulating properties.
- Good abrasion and strain resistance.
- High dimensional stability (Mechanically strong and stable over time)
- High surface brightness and excellent surface aspect.
MANUFACTURING PROCEDURE :
Injection Molding
It is a manufacturing process used for the mass production of plastic components. It works by injecting molten material(plastic) into a mold. Under the application of heat and pressure, the material solidifies into the required shape. Once the product cools, it is ejected from the mold with the help of ejector pins.
DOG HOUSE
Dog house is an engineering feature used in plastic trim design. Dog houses are used as supporting feature. Sometimes other engineering features like snaps; locators etc. are mounded on them to increase their strength. Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from mould cavity. Dog house and other engineering components are built on B-surface.
GUIDE LINES OF DOG HOUSE
C- is where doghouse contacts back side of surface.
Dog house wall thickness at intersection of partwaqll(c) should be 40% or less than main wall stock(T).
Height of (B) should be between 3-6mm.
dog house draft outer faces -1.5 degree
dog house inner face draft-0.5-1 degree
Coring or sink mark cut 3-6mm
height of the dog house is 60mm
dog house outside fillets -3.5mm
dog house inside fillet- 1mm
HEAT STAKING
Heat staking also known as thermoplastic staking is the process of joining two dissimilar materials together. In heat staking we use 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.
Applications range from staking plastic boss’s for assembly of car door panels to joining PCB’s to plastic housings. Benefits of this technique include; no vibration damage, no particulates, the ability to stake metalized coated applications and the capability to stake in difficult to access or restricted areas.
CLASS A OF DOOR TRIM PANEL
PARTS OF DOOR TRIM PANEL:
LOWER SUBSTRACTE CLASS A
CLASS A SURFACE : Asurface is the aesthetic surface created by the class-A engineer. It is the visible aesthetic surface of any automotive component. class A surface is any of a set of freeform surfaces of high efficiency and quality.
TOOLING AXIS
TOOLING AXIS : Tooling axis means the direction in which core and cavity open and close.Tool is nothing burt mold, tooling axis is created to know in which direction the mold open and close, parts drafts are given along this axis.
DRAFT ANALYSIS FOR CLASS A
DRAFT ANALYSIS : Draft analysis is done to check weather the tooling axis and draft angle are correct or not and to find weather the component is manufactured and ejected or not. Draft Analysis is a tool in CATIA which identifies the zones which deviates from the specified values of angles along a defined draft direction using colour codes.
CLASS B
CLASS B SURFACE : B surface is the offset of the class A surface. Class B surfaces are Engineering Surfaces which are invisible to the eyes or often on the back side of the Class A surfaces. It is mainly the thickness of the component or Class A.
CLASS C
CLASS C SURFACE : C surface is joining surface between A and C. Class C surfaces are connectors between Class A and B surfaces. This surface connects both A and B surfaces along the Tooling Axis. It contains the draft as per the design. Its is basically the thickened surface between both A and B surface.
CLOSED SURFACE BODY
FINAL DRAFT ANALYSIS
DRAFT ANALYSIS : Draft analysis is done to check weather the tooling axis and draft angle are correct or not and to find weather the component is manufactured and ejected or not. Draft Analysis is a tool in CATIA which identifies the zones which deviates from the specified values of angles along a defined draft direction using colour codes.
SOLID BODY
UPPER SUBSTRACTE CLASS A
CLASS A SURFACE : Asurface is the aesthetic surface created by the class-A engineer. It is the visible aesthetic surface of any automotive component. class A surface is any of a set of freeform surfaces of high efficiency and quality.
TOOLING AXIS
TOOLING AXIS : Tooling axis means the direction in which core and cavity open and close.Tool is nothing burt mold, tooling axis is created to know in which direction the mold open and close, parts drafts are given along this axis.
DRAFT ANALYSIS
DRAFT ANALYSIS : Draft analysis is done to check weather the tooling axis and draft angle are correct or not and to find weather the component is manufactured and ejected or not. Draft Analysis is a tool in CATIA which identifies the zones which deviates from the specified values of angles along a defined draft direction using colour codes.
CLASS B
CLASS B SURFACE : B surface is the offset of the class A surface. Class B surfaces are Engineering Surfaces which are invisible to the eyes or often on the back side of the Class A surfaces. It is mainly the thickness of the component or Class A.
CLASS C
CLASS C SURFACE : C surface is joining surface between A and C. Class C surfaces are connectors between Class A and B surfaces. This surface connects both A and B surfaces along the Tooling Axis. It contains the draft as per the design. Its is basically the thickened surface between both A and B surface.
CLOSED SURFACE
FINAL DRAFT ANALYSIS
DRAFT ANALYSIS : Draft analysis is done to check weather the tooling axis and draft angle are correct or not and to find weather the component is manufactured and ejected or not. Draft Analysis is a tool in CATIA which identifies the zones which deviates from the specified values of angles along a defined draft direction using colour codes.
SOLID BODY
DOOR ARM REST CLASS A
CLASS A SURFACE : Asurface is the aesthetic surface created by the class-A engineer. It is the visible aesthetic surface of any automotive component. class A surface is any of a set of freeform surfaces of high efficiency and quality.
TOOLING AXIS
TOOLING AXIS : Tooling axis means the direction in which core and cavity open and close.Tool is nothing burt mold, tooling axis is created to know in which direction the mold open and close, parts drafts are given along this axis.
DRAFT ANALYSIS
DRAFT ANALYSIS : Draft analysis is done to check weather the tooling axis and draft angle are correct or not and to find weather the component is manufactured and ejected or not. Draft Analysis is a tool in CATIA which identifies the zones which deviates from the specified values of angles along a defined draft direction using colour codes.
DRAFT ANALYSIS
CLASS B
CLASS B SURFACE : B surface is the offset of the class A surface. Class B surfaces are Engineering Surfaces which are invisible to the eyes or often on the back side of the Class A surfaces. It is mainly the thickness of the component or Class A.
CLASS C
CLASS C SURFACE : C surface is joining surface between A and C. Class C surfaces are connectors between Class A and B surfaces. This surface connects both A and B surfaces along the Tooling Axis. It contains the draft as per the design. Its is basically the thickened surface between both A and B surface.
CLOSED SURFACE
CLOSED SURFACE DRAFT ANALYSIS
DRAFT ANALYSIS : Draft analysis is done to check weather the tooling axis and draft angle are correct or not and to find weather the component is manufactured and ejected or not. Draft Analysis is a tool in CATIA which identifies the zones which deviates from the specified values of angles along a defined draft direction using colour codes.
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SOLID BODY
MAP POCKET WITH BOTTLE HOLDER CLASS A
CLASS A SURFACE : Asurface is the aesthetic surface created by the class-A engineer. It is the visible aesthetic surface of any automotive component. class A surface is any of a set of freeform surfaces of high efficiency and quality.
TOOLING AXIS
TOOLING AXIS : Tooling axis means the direction in which core and cavity open and close.Tool is nothing burt mold, tooling axis is created to know in which direction the mold open and close, parts drafts are given along this axis.
DRAFT ANALYSIS
DRAFT ANALYSIS : Draft analysis is done to check weather the tooling axis and draft angle are correct or not and to find weather the component is manufactured and ejected or not. Draft Analysis is a tool in CATIA which identifies the zones which deviates from the specified values of angles along a defined draft direction using colour codes.
CLASS B
CLASS B SURFACE : B surface is the offset of the class A surface. Class B surfaces are Engineering Surfaces which are invisible to the eyes or often on the back side of the Class A surfaces. It is mainly the thickness of the component or Class A.
CLASS C
CLASS C SURFACE : C surface is joining surface between A and C. Class C surfaces are connectors between Class A and B surfaces. This surface connects both A and B surfaces along the Tooling Axis. It contains the draft as per the design. Its is basically the thickened surface between both A and B surface.
CLOSED SURFACE
FINAL DRAFT ANALYSIS
DRAFT ANALYSIS : Draft analysis is done to check weather the tooling axis and draft angle are correct or not and to find weather the component is manufactured and ejected or not. Draft Analysis is a tool in CATIA which identifies the zones which deviates from the specified values of angles along a defined draft direction using colour codes.
SOLID BODY
FINAL DOOR TRIM PANEL
