Week 11 - Final project

Projec Title : DEVELOPMENT OF A DOOR TRIM PANEL

OBJECTIVE :

The Objective of the project is to development of vehicle interior door trim panel by using CATIA V5 With given class-A surface along with the master seection. Also Create the side attachment feature as per design rules.

INTRODUCTION :

The door panel is the interface between the interior of the car and inner working of the door. Generally, the door panel is divided into parts for easy designing like arm rest, map pocket, Lower substrate. These require one of the toughest requirements amoung the interior parts of the car. This should be designed to with stand the load while being less than 2mm thickness and also to protect the occupants during collisions.

Class-A Surfaces :-

In automotive design a Class-A surface in any of a set of from surface of high efficiency and quality. Although strictly its nothing more than saying have curvature alignement to ideal aesthetical reflection quality, many people interpret class-A surface to have G2 or even G3 curvature continuity to one another. Class-A surface is creating by using computer Aided digital applications. Class-A surface modellers are also called digital sculptors in the industry.

Class-B Surface :-

Class B surface are Engineering Surfaces which are invisible to the eyes or often on the back side of the Class A surface. It is mainly the thickness of the component or Class A. These surfaces need to be designed as per the Class A surface i.e., the continuity, thickness of the component, functionality etc should be maintained. These surfaces include the main engineering features such as Screw bosses, Ribs, Snaps, Stiffeners and fixations. B surfaces also do not contain any aesthetic styling content and textures since it is not visible to eyes.

Class- C Surface :-

Class C surfaces are connectors between Class A and Class B surfaces. This surface connects both A and B surfaces along the tooling Axis. It contains the draft as per the design. It is basically the thickened surface between both A and B surface.

Tooling Axis:

Tooling Axis is the direction in which the Mold opens and closes. Part Drafts are generally given along this axis.

3) DESIGN METHODOLOGY OF DOOR TRIM PANEL :

4) PROCEDURE OF DOOR TRIM PANEL :

The door panel is divided into four parts for easly to design. There are,

1. Door Arm Rest.
2. Lower substrate.
3. Outer Map Pocket.
4. Inner Map Pocket.

A) Door Arm Rest :-

Step 1: Design Check (Pre Check) on received Class A :-

• After receiving the Class-A for the connectivity of the surfaces on it.
• Use boundary operation and disassemble.
• Check for discontinuous Surface.
• The check is over if any discontinuities do not arise.

Step 2: Determine the tooling Axis :-

• Identify faces which can potentially create problems while manufacturing.
• Surfaces at angles along a desired Tooling Axis.
• Extract a plain surface and create a point on its center for Axis system creation.

Step 3: Draft Analysis on Class-A and Possible Creation of Side Tooling Axis :-

• Change View Mode Customization to Material mode.
• Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
• Change the range to 3°. Apply the settings as shown in below image.

• The input Class A also has walls having negative angle to the tooling axis.
• This can be an issue while manufacturing the component as it would be very difficult to draw from the molds.
• So, this design needs to consider Various Side Tooling Options.

• Here also we can see that some faces are not clearing draft analysis and it is due to the improper class A surface and we have to imform our styling team to modify the class A surface.

Step 4: Class-B Surface Creation :-

This can be done by offseting the class-A surface and by reparing the patches that are forrmed while offsetting the class-A surface.

• First offset the class-A surface
• We can observe it has created patches at two stages.
• So we have to repair them by using multi section surface command.
• Name the developed repaired surface ass Class-B Surface and make it publish.

Step 5: Class-C Surface Creation :-

• Extract Class A boundary and convert to Smooth Curve.
• Sweep the curve to the Class A.
• Sweep value should be greater than the Thickness required for part.
• The obtained sweep is shown in Figure.
• Join the Class A Surface with the Class C surface to create a single surface entity.

Step 6: Enclosed Surface Creation :-

• Trim the obtained surface with Class B surface.
• Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
• The final Enclosed Surface Obtained is shown in Figure.

Closed Surface :-

Make the final trim to solid part using close surface.

Step 7: Perform Draft Analysis on Final Enclosed Surface:

• Change View Mode Customization to Material mode.
• Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
• Change the range to 3°. Apply the settings as shown if Figure.

Views of Door Arm Panel :

B) Lower Substrate :-

Step 1: Design Check (Pre Check) on received Class A :-

• After receiving the Class-A for the connectivity of the surfaces on it.
• Use boundary operation and disassemble.
• Check for discontinuous Surface.
• The check is over if any discontinuities do not arise.

Step 2: Determine the tooling Axis :-

• Identify faces which can potentially create problems while manufacturing.
• Surfaces at angles along a desired Tooling Axis.
• Extract a plain surface and create a point on its center.
• Create the intersection by using the plane.
• Create the bisecting line for tooling axis by taking dummy tooling axis.

Step 3: Draft Analysis on Class-A :-

• Change View Mode Customization to Material mode.
• Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
• Change the range to 3°. Apply the settings as shown in below image.

Step 4: Class-B Surface Creation :-

• The creation of class-B surface can be done by smiply offsetting the class-A surface to the required distance and required direction.

Step 5: Class-C Surface Creation :-

• Extract Class A boundary and convert to Smooth Curve.
• Sweep the curve to the Class A.
• Sweep value should be greater than the Thickness required for part.
• The obtained sweep is shown in Figure.
• Join the Class A Surface with the Class C surface to create a single surface entity.

Step 6: Enclosed Surface Creation :-

• Trim the obtained surface with Class B surface.
• Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
• The final Enclosed Surface Obtained is shown in Figure.

Closed Surface :-

Make the final trim to solid part using close surface.

Step 7: Perform Draft Analysis on Final Enclosed Surface:

• Change View Mode Customization to Material mode.
• Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
• Change the range to 3°. Apply the settings as shown if Figure.

Views of Lower Substrate :

C) Outer Map Pocket :-

Step 1: Design Check (Pre Check) on received Class A :-

• After receiving the Class-A for the connectivity of the surfaces on it.
• Use boundary operation and disassemble.
• Check for discontinuous Surface.
• The check is over if any discontinuities do not arise.

Step 2: Determine the tooling Axis :-

• Identify faces which can potentially create problems while manufacturing.
• Surfaces at angles along a desired Tooling Axis.
• Extract a plain surface and create a point on its center for Axis system creation.

Step 3: Draft Analysis on Class-A :-

• Change View Mode Customization to Material mode.
• Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
• Change the range to 3°. Apply the settings as shown in below image.

Step 4: Class-B Surface Creation :-

• The creation of class-B surface can be done by smiply offsetting the class-A surface to the required distance and required direction.

Step 5: Class-C Surface Creation :-

• Extract Class A boundary and convert to Smooth Curve.
• Sweep the curve to the Class A.
• Sweep value should be greater than the Thickness required for part.
• The obtained sweep is shown in Figure.
• Join the Class A Surface with the Class C surface to create a single surface entity.

Step 6: Enclosed Surface Creation :-

• Trim the obtained surface with Class B surface.
• Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
• The final Enclosed Surface Obtained is shown in Figure.

Closed Surface :-

Make the final trim to solid part using close surface.

Step 7: Perform Draft Analysis on Final Enclosed Surface:

• Change View Mode Customization to Material mode.
• Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
• Change the range to 3°. Apply the settings as shown if Figure.

Views of Outer Map Pocket :

D) Inner Map Panel :

Step 1: Design Check (Pre Check) on received Class A :-

• After receiving the Class-A for the connectivity of the surfaces on it.
• Use boundary operation and disassemble.
• Check for discontinuous Surface.
• The check is over if any discontinuities do not arise.

Step 2: Determine the tooling Axis :-

• Identify faces which can potentially create problems while manufacturing.
• Surfaces at angles along a desired Tooling Axis.
• Extract a plain surface and create a point on its center.
• Create the intersection by using the plane.
• Create the bisecting line for tooling axis by taking dummy tooling axis.

Step 3: Draft Analysis on Class-A :-

• Change View Mode Customization to Material mode.
• Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
• Change the range to 3°. Apply the settings as shown in below image.

Step 4: Class-B Surface Creation :-

• The creation of class-B surface can be done by smiply offsetting the class-A surface to the required distance and required direction.

Step 5: Class-C Surface Creation :-

• Extract Class A boundary and convert to Smooth Curve.
• Sweep the curve to the Class A.
• Sweep value should be greater than the Thickness required for part.
• The obtained sweep is shown in Figure.
• Join the Class A Surface with the Class C surface to create a single surface entity.

Step 6: Enclosed Surface Creation :-

• Trim the obtained surface with Class B surface.
• Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
• The final Enclosed Surface Obtained is shown in Figure.

Closed Surface :-

Make the final trim to solid part using close surface.

Step 7: Perform Draft Analysis on Final Enclosed Surface:

• Change View Mode Customization to Material mode.
• Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
• Change the range to 3°. Apply the settings as shown if Figure.

Views of Inner Map Pocket :

5) VIEWS OF DOOR TRIM PANEL ASSEMBLY :

• Front View

• Back View

• Left View

• Right View

• Top View

• Bottom View

• Isometric View

6) DESIGN OF B-SIDE FEATURES :

• First Create Flanges where ever required on the part bodies. The purpose of flange is to accomodate heatstakes on the part bodies.
• After creating the flanges create heat stakes at the places where flanges are present. For the thickness and diameter of the heat stakes refer to the master section which is given in the challenge.
• Then create a clearance hole on the flanges which we have created previously. The clearance between flange and heat stake must be 0.1mm.
• After creating the heat srakes create ribs on the lower substrate. The main purpose of creating ribs is to support the flange as well as ribs under the application of large pressure and force when the process of melting heat stakes is happening.

Then after attach the push pin to the dog house by using proper assembly constraints.

7) Views of the final assembly of Door Trim Panel :

Front View

• Back View

• Left View

• Right View

• Top View

• Bottom View

• Isometric View

DRAFT ANALYSIS:

PUSH PIN:

8) Tree Structure :

9) CONCLUSION :

Class-B and Class-C Surfaces are created to the given Class-A surfaces. The design of B-side features is done and they are assembled successfully. A detailed report has been prepared and all the part bodies and assembly has been attached to the challenges successfully.