Week 11 - Final project

1. Development of aDOOR TRIM PANEL using CATIA- V5

Creation of CAD model considering following inputs as like in OEM and tier1 companies

1. a) Class A surface
2. b) Nominal thickness : Refer master sections
3. c) Attachment strategy : 

Find a attachment strategy for the door panel complete work.

Use Push pin with Dog house for Lower substrate – Door panel attachment

Use heat stakes for part to part attachment

Output required:

• Create thickened part using master section for reference
• Create the mounting features as per design guidelines in the industry and with master sections
• Apply material details : 
• Draft analysis & Tooling analysis
• Creation of parting lines and check tooling feasibility

Output required in attachment 

• Submit the CATpart and CATproduct in the attachment

Project Overview:

Door Trim is the interior component attached to the interior side of the door. It's a vital component which provides aesthetic look to the interior of the car and also provides features and functions for the passengers. In this project we are going to design the lower portion of the door trim from the given Class-A Surface. Also we would be designing the B-Side Features on the component by following the industry standards and design rules.

INTRODUCTION:-

Side Door Plastic Trim

An interior plastic component attached to the inner side of the door. This product improves the appearance of the vehicle intertior and also creates a more comfortable interior by providing a variety of fitments and functions.

 

Workbench and its Toolbar used:

Generative Shape Design Workbench

• Surface Toolbar
• Wireframe Toolbar
• Operation Toolbar

Part Workbench

• Sketch Based Feature Toolbar
• Dress up Features Toolbar
• Surface Based Feature Toolbar

Assembly Workbench

• Constraints (Coincidence ,contact, angle offset)
• Assembly features
• move
• Product Structure Tools

INTRODUCTION 

MASTER SECTION: Master sections development takes place during feasibility check and concept validation stages of the product life cycle. These are typically the guides for design requirements and which decides the component packaging after the development of the concept design, i.e class A surfaces. 

Master section helps us to decide the feasibility of the concept design, the clearances, the packaging and the fixation strategy of a component before converting the concept design into a solid 3D engineering design.

During the period of vehicle concept design, the evaluation of the master section performance depends mainly on the reference vehicle data and the experience of the structural design engineer. 

DESIGNING METHODOLOGY:

IMPROVING THE CLASS A SURFACE

The given class A surface is not a proper surface for Door Arm Rest because it is lacking the side Fillets so first thing that we have to do is to remove smaller Fillet from Class A surface Brcause it is not possible to take offset of it in B sur surface.

also we are havving some open Boundries in Given Input Class A surface

Also We are removing sharp corner from class a surface by Splliting Command.

Steps followed

• The class A surface is checked for the connectivity of the surface and ensure it is completely joined and there will be no gap between the surfaces.
• If it is not join together make it with a minimum tolerance of 0.001 to 0.003 and check for connectivity of the surface.
• Connectivity of the surface can be done by two ways by join method and by boundary method.
• Split the surfaces into multiple profiles then Identify the surface where it is not possible to create a tooling axis by following the minimum draft angle and check on which direction is best fit for tooling axis and then define the tooling axis and draft direction.
• Here for defining the tooling axis first we have created a point at middle of the base surface and create an axis with respect to that point then define the tooling axis using the intersect method by creating a bisecting line.
• Then do a draft analysis on the class A surface and identify the draft angle then give the nominal value for the draft.

Tooling axis creation

• The direction in which the mould open and closes is called the tooling axis direction.
• Check the connectivity of the surface and ensure there will be no gap between the surfaces and then define the tooling axis.
• While creating a tooling axis please ensure to give the tooling axis on a flat length surface or the surface which have a hole on it.
• Create a point on the middle of the base surface by using point on the surface command then create a intersection for the surface and extract the reference lines which will be helpful for creating the dummy tooling axis using the intersect method by creating a bisecting line..
• Use the line command and draw the lines which is aligned with the extracted lines and extended it to the required length.

Bisecting method

• Identify on which plane we have to do more operations and create the plane or axis on the component area define it on the dummy tooling axis direction.
• Intersect the class A surface with that plane then we will get a intersection sketch. Look for the profile (inclined line) which will create a problem and extract it then extending it by using line command.
• Then create a bisecting lines with reference to the lines we have extended and this will be our main tooling axis.
• In this case we have created tooling axis along with Y direction with reference to the base surface.

But in Our Project We Created Tooling Axis By Extracting The Surface and Drawing line  by POINT - DIRECTION 

Draft analysis

• Draft allows for the component to release from the mould, most parts or applications require a minimum of 0.5 to 1 degree draft angle and 3 dgree draft angle is widely used as per the norm.
• Change the material mode to customize mode before moving to the draft analysis.
• Insert –analysis-feature draft analysis
• Defining the draft direction Select draft analysis from the tool bar and click on the compass symbol and pull the compass from the right side top corner of the workbench and place it on the component where want to do the draft analysis. ‘W’ of the compass and tooling axis should be aligned on the same line.
• Once the compass is aligned with the tooling axis click on the lock symbol and drag on the surface we will get a wrong mark then select that point a table will appear it shows the draft value on the table we can adjust the draft value and analysis it for all the edges and surfaces.
• By clicking the on the surface and using the flipping tool we can assign the Flipping direction, the color of the surface change as per the flipping direction .
• Analysis under running point and move the mouse on the surface and it will show the details of the surface deg direct at each and every point of the surface.

Pre requisites before creating the tooling axis and performing draft analysis-

1. Ensure that the Class A surface imported should be a single surface.
2. This can be checked using the Boundary tool in the Operation Toolbar.
3. If the surfaces are disassembled, join them using Join command which is also found in the Operation toolbar.

Creating any component from Class A Surface ( Overview ) -

1. Decide a suitable tooling axis direction and create the Tooling Axis.
2. Perform Draft analysis for analyzing whether the drafts on the component follow the industry standards.
3. Create another surface ( B Surface ) offset to the Class-A Surface. The offset distance should be equal to the thickness of the component.
4. Create a C- Surface ‘Sweeping’ the boundary of Class-A -Surface along the Tooling Axis.
5. Trim Class- A surface with B-Surface and C Surface to create a closed surface.
6. Finally create the solid part from this surface to obtain the desired component.

Procedure:

I] Visual Analysis of Class-A Surfaces:

Firstly we observe the Class-A Surface and understand how the component can be manufactured.

Observing the Master Sections:

The procedure of Draft Analysis is as follows-

1. Before starting the draft analysis ensure that the ‘Materials’ option is selected under Customize View Parameters in order to view the results of the analysis.
2. Click on Insert >> Analysis >> Feature Draft Analysis.
3. Draft analysis window will be opened having three sections - Mode , Display and Direction. 
4. In the Display section select the compass and drag it onto your component. Place it along the tooling axis.
5. Lock the direction of the draft.   
6. Another window will be displaying ranges of draft on the component. The ranges are - Green for more than zero , Red for zero and Blue for negative draft value. 
7. Assign the lower limit as 3 deg to the Green range from the value edition dialogue box.
8. Once you do it, click on the component to see the results.
9. You can also check the draft value at any point using the ‘Analysis under running point' option in the Display Section. 

MINIMUM DRAFT FOR THE COMPONENT = 3 DEG

DRAFT ANALYSIS ON CLASS A SURFACE 

LOWER SUBSTRATE

ARM REST WITH MAIN TOOLING AXIS

WITH SIDE CORE AXIS

BOTTLE HOLDER 

Here ,Now we are going to develope the CLOSED BODY from provided Inputs and Master Section of Door Panel.....