Week 11 - Final project

DOOR TRIM PANEL

Aim:

To Create the Door trim panel component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

Objective:

• To design lower substate as per automotive OEM Standard.
• Create B Class and C Class and tooling axis.
• Converting close surface into the solid inside part workbench and provide the thickness of 2.5mm.
• Performing draft analysis to verify the creation of the Tooling axis and C Class surface.
• Creating Engineering Features.

Operations:

• Creating tooling axis.
• Create draft analysis
• Creating Class B surface.
• Creating Class C surface.
• Final product using closed surface.
• To create heat stakes, locators and dog house.

The Parts to be create:

1. Door Arm rest
2. Lower Substate
3. Map Pocket
4. Map Pocket with bottle holder.

The material used in those surface are :

• Acrylonitrile Butadiene Styrene (ABS).

ACRYLONITRILE BUTADIENE STYRENE(ABS):

High Rigidity:

• ABS has high rigidity and impact resistance. Even in low-temperature conditions or over long periods, ABS plastics will retain these characteristics.
• Its tensile strength is around 35-44 Mpa and because of its plastic yield at high strain rates, the impact failure of ABS is ductile rather than brittle.
• It is used in Instrument-Panel, Door-trims,Coin holder etc. As it has good impact resistance, it is used in creating bumpers as well.

Excellent Insulation:

• It has very good insulating properties, both acoustic and thermal.

Highly Weldable:

• It is a good weldable material as it is an amorphous material
• It is usually measured in terms of stiffness or modulus.

High Dimensional Stability:

• It remains mechanically strong over time.

Good Surface Characteristics:

• High Surface brightness and excellent surface finish. ABS is an ideal material whenever superlative surface quality, color fastness, and luster are required. ABS is a two-phase polymer blend.
• A continuous phase of ‘Styrene-Acrylonitrile’ co-polymer(SAN) gives the material rigidity. Hardness and heat resistance. The toughness of ABS is the result of microscopically fine polybutadiene rubber particles uniformly distributed in the SAN matrix.
• Hence, ABS is also used in Wheel-covers, IP substrate, etc

Good Abrasion & Strain Resistance

Followed Constraints:

• The thickness given to all the part is 2.5 mm.

Engineering Features:

HEAT STAKES:

• Heat staking also known as thermoplastic staking is the process of joining two dissimilar materials together.
• It is also known as permanent joining method. 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. IT consist of ribs.

Guidelines to create Heat Stakes:

• Height of the heat stake consist of. Rib height - (3 - 6 mm); Counterpart height - (>= 2 mm ); Staking part - (12 mm).
• Inner dia - 5 mm
• Outter dia - 7 mm
• Depth of inner Dia - (2.5 - (0.5 t))
• Total width of rib - 22 mm
• Draft angel - 0.5 deg
• Fillet radius - (0.5 mm)

Flanges:

• Flanges are used with heat stakes for permenanet joint with another part. Flanges are also added strength to the part.

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 house wall thickness at intersection of part wall (c) should be 40% or less than main wall stack (T).

Guidelines to create Dog House:

• Width of the DogHouse - (25 - 35mm).
• Height of the Dog House - (45 - 60mm).
• Outter Draft - (> 0.3 deg), Nominal = 1.5 deg.
• Inner Draft - (> 0.1 deg), Nominal = 0.5 deg.
• Thickness - Nominal Wall thickness.
• Height of the Sink mark cut - (3 - 6mm).
• Fillets can be given according to the thichness rule.
• Width of one dog house to another dog house is (w x 3).

Tooling Axis:

• The tooling axis for this component will be created from the Y component. This should be done using the method of extracting the plane surface and Creating a point in the plane using a point on the surface. And finally, the line should create using the normal surface.

1) Lower Substate

2.Door Arm Rest:

3.Map pocket:

4.Map pocket with bottle holder:

LOCATORS:

2 WAY LOCATORS:

A 2-way locating pin restricts motion along 1 axis (or 2 degrees of Freedom), like a round pin in a slot. Likewise, a 4-way pin restricts 4 degrees of freedom along 2 axes. A round locating pin located concentrically in a hole is a common application of a 4-way pin, and helps to further secure the piece.

4-WAY LOCATORS:

A round locating pin located concentrically in a hole is a common application of a 4-way pin, and helps to further secure the piece. 4-WAY LOCATORS: 4-way mean you prevent movement at 2 axes (+X, -X, +Y and -Y) on the plane. Generally, you have cylindrical pin on the fixture and circular hole at workpiece part.

CLASS C MAP POCKET BOTTLE HOLDER:

CLASS A & C:

CLASS A & B & C:

CLASS C MAP POCKET:

CLASS A & C:

CLASS A & B & C:

MAP POCKET FINAL DRAFT ANALYSIS:

DOORM ARM REST CLASS C:

CLASS A&B&C:

DOOR ARM REST DRAFT ANALYSIS:

CLASS C LOWER SUBSTATE:

CLASS A & C LOWER SUBSTATE:

CLASS A & B & C LOWER SUBSTATE:

LOWER SUBSTATE DRAFT ANALYSIS:

FINAL PART:

MAP POCKET BOTTLE HOLDER TREE:

MAP POCKETTREE:

DOOR ARM REST TREE:

LOWER SUBSTATE: