Week 11 - Final project

AIM:

To design and develop vehicle interior door trim using Catia V5 with a given class A surface along with the Master section. Also create the Side Attachment features as per design rules.

 

OBJECTIVE:

• To create thickened part using master section for reference
• To create the mounting features as per design guidelines in the industry and with master sections
• To perform Draft analysis & Tooling analysis.

MATERIALS USED IN DOOR TRIM LOWER : 

ABS, PC/ABS, PP compounds and TPE Solutions meet the demand for outstanding interior door components. Our high-performance products satisfy industries' increasing expectations for storage, comfort, and outstanding haptics.

• Very good processability results in design flexibility and enables thin walling for weight reduction and/or shorter cycle times
• High durability through dimensional stability, aging and heat resistance (ranging from -40°C to 125°C)
• Low VOC and odor for enhanced air quality
• High scratch resistance of PP and elastomer-based products
• Optimized appearance and haptics (colorability, uniform low/high gloss properties, graining)

In these materials ABS is widely used among other materials in the industry as it is having the strong durability.

ABS or Acrylonitrile butadiene styrene is a common thermoplastic polymer typically used for injection molding applications. This engineering plastic is popular due to its low production cost and the ease with which the material is machined by plastic manufacturers. Better yet, its natural benefits of affordability and machinability do not hinder the ABS material’s desired properties:

• Impact Resistance
• Structural Strength and Stiffness
• Chemical Resistance
• Excellent High and Low Temperature Performance
• Great Electrical Insulation Properties
• Easy to Paint and Glue

ABS plastic attains these physical attributes through the initial creation process. By polymerizing styrene and acrylonitrile in the presence of polybutadiene, chemical “chains'  attract each other and bind together to make ABS stronger. This combination of materials and plastics provides ABS with superior hardness, gloss, toughness and resistance properties, greater than that of pure polystyrene.

CATIA:

      It means Computer-Aided Three-Dimensional Interactive Application.  It is computer aided designing software. This is software which is used to design 3D models with different workbenches.

   CLASS A SURFACE:

                 It is a surface which is made by the designer. It is an aesthetic surface and usable outside futures are on this surface.

  CLASS B SURFACE:

           It is at the bottom of class A surface. It is made of class A surface. It is formed with a thickness distance from class A surface.

  CLASS C SURFACE:

        It joins both class A and class B surfaces. This surface is equal to the thickness of the component.

TOOLING AXIS:

• Class A surface or part is used to manually analyze which is best for tooling and create the axis perpendicular to the product. It is called the tooling axis. Mold is open and closed by this axis.

DOG HOUSE:   

  It is used mainly for three functions.

• To eliminate the sink marks
• To lift the bosses for hight
• To give outside bosses from B surface

RIBS:

     Ribs give strength to the model. It is made by some guidelines like draft, filets etc.

MASTER SECTION:

       They check and give a new alteration model in 2D with class A surface which is used to make a 3D model for next step designing.

METHODOLOGY:

Part body:

 

TOOLS:

1. Extract:

    This comment is used to create the required surface again. Which means copy the surface again for next operations.

1. Un trim:

   This tool is used to un trim the surface which means creating the full surface of the previous surface from the current surface.

1. Trim:

      This tool is used to cut and eliminate the unwanted surface.

1. Extrapolated:

       This tool is used to increase the length of surface or area with the help of different options.

1. Offset:

It is used to create the same surface again in required distance.

1. Edge Filet:

It is used to create sharp edges to round edges.

1. Boundary:

         It is used to form the boundary lines on an open surface.

1. Sweep:

          It is used to create the surface in required length from the profile.

1. Join:

         It is used to join the separate surfaces and create the single surface.

1. Close (Part command)

        It is used to create the solid part from the closed hollow part.

1. Curve smooth:

                It is used to change the smooth curve from tangency curve.

1. Fill:

              Fill some gaps portion with this comment

1. Blend:

                Two bounty lines used to fill the gaps by this comment.

     14.Split:

            It is used to separate the surface with the help of another surface as a cutting tool.

1. Pad:

             It is used to extrude to create 3D parts from 2D sketches.

   16.Thicken:

                It is used to give thickness to the surface model. It is one of the part bench comments.

CLASS A SURFACE:

CLASS A SURFACE : MAP POCKET WITH BOTTLE HOLDER 

CLASS A SURFACE : MAP POCKET

CLASS A SURFACE : DOOR ARMREST

 

CLASS A SURFACE : LOWER SUBSTRATE

 

 TOOLING AXIS CREATION:

• First create the class A surface and manually analyze and fix the direction of tooling.
• In this part two holes on the surface. So, we can directly take its perpendicular as the tooling axis because it's most suitable for tooling axis. Carefully watch and take this axis with the help of all types of views.
• First create the point on the surface and create a new axis system.
• Then this intersect line is used to create the new lines on both wall lines. Then the both lines are used to create a bisecting line in tooling direction or it is zero degree drafting part, so we directly draw line through the line to form the tooling axis.
• Change some appearance to this line like thickness, color, dot lines. Finally, it is called the tooling axis. It is published for frequent uses.
• Dog house is created by the side core. So, we created a separate tooling axis for the dog house. Same method is used to create a tooling axis perpendicular to the main axis.

 TOOLING AXIS CREATION: MAP POCKET WITH BOTTLE HOLDER:

 

TOOLING AXIS CREATION: MAP POCKET

 

TOOLING AXIS CREATION: DOOR ARMREST

.

TOOLING AXIS CREATION: LOWER SUBSTRATE

 

CLASS B SURFACE CREATION:

            Following procedures are used to create surface B class.

1. We directly offset the given bumper surface at 3mm distance inside with the help of offset comment fore b surface
2. Some discontinuous surface filled with some comment like blend, fill, Mss etc.
3. If we need any bounty expand with the help of extrapolated comments.
4. Trim unwanted surface
5. Finally, we got surface B class.

CLASS B SURFACE : MAP POCKET WITH BOTTLE HOLDER

 

CLASS B SURFACE : MAP POCKET

 

CLASS B SURFACE :DOOR ARMREST

 

CLASS B SURFACE : LOWER SUBSTRATE

 

SURFACE C CLASS CREATION:

1. Extract tool is used to create the boundary lines separately on side edges of class A surface
2. Sweep comment is used to create surface C class for separate edges from a given master section reference. Finally merge all sweep surfaces to get class C surface.

CLASS C SURFACE : MAP POCKET WITH BOTTLE HOLDER

 

CLASS C SURFACE : MAP POCKET

.

CLASS C SURFACE : DOOR ARMREST 

 

CLASS C SURFACE : LOWER SUBSTRATE

 

FINAL PART:

1. Join command is used to join the surface A class and the surface A, C class
2. Trim command is used to trim class AC and B. They join themselves.
3. Finally, we got a hollow product.
4. In part bench close command is used to get the solid model
5. We give different colors to appearance and easily analyze different parts.

FINAL PART : MAP POCKET WITH BOTTLE HOLDER

 

FINAL PART : MAP POCKET

 

FINAL PART : DOOR ARMREST

 

FINAL PART : LOWER SUBSTRATE

 

DOG HOUSE:

1. First draw the rectangle with one side open
2. Extrude required height or given height 30mm.
3. Offset used to close the top side
4. Give thickness to the surface part 2.5mm.
5. Give drafting to the outside surface 1.5 degree.
6. Give inside and outside filets
7. Then follow some dog house standard instructions like downside thickness and height and some values.
8. Offset the previous surface part 1mm and downside surface offset upside 4mm
9. Trim and form down side part
10. This part split from previous part body
11. Give draft and filet to the top wall of the split portion. This draft is given for the side core so we create a separate tooling axis perpendicular to the main tooling axis and give a draft for this direction.
12. Finally, we have got a dog house. Next, we will create the ribs on the dog house's middle surface.
13. So, we created the middle part separately.

REMASTERED DOG HOUSE

 

 CLOSED SOLID BODY WITH FLANGES,DOG HOUSE, HEATSTAKES AND RIBS:

Closed solid part body with flanges, dog house, heat stakes, and ribs is  added to the closed Part body of each part in the necessary dimensions and in required locations.

• MAP POCKET WITH BOTTLE HOLDER

 

• MAP POCKET:

 

• DOOR ARMREST:

• 
• LOWER SUBSTRATE:

 

DRAFTING ANALYSIS:

Drafting analysis procedure is used to analyze the drafting angle. It is used to determine the drafting angle of a part in different positions by main tooling axis and side core tooling axis.

• MAP POCKET WITH BOTTLE HOLDER

• MAP POCKET

• DOOR ARM REST

• LOWER SUBSTRATE

 

WHOLE  SOLID PARTS : 

CONCLUSION:

 Different commands are used to create the surface A class, B class, C class. Then join and convert the solid. Finally, the B surface and solid part of door trim are created from the provided class A surface. Dog houses with ribs are created by standard guidelines. Full model is successfully created by the master section and the draft is analyzed by CATIA software.