Week 11 - Final project

                                                                             FINAL PROJECT

                                                                           DOOR TRIM PANEL

INTRODUCTION:

              The final project of door trim panel has four majer components and also the B side features.Class A surface as an input and created the Class B,C and converted into solid part with proper draft angle and parting line which used for the reference creation of core and cavity. The Class B side features have been created for the all closed body.Consideribg the design rules the class B side features has created.Then Draft analysis has created in all the final parts.

        Major components of door trim panel are:

1. Door arm rest
2. Map pocket
3. Bottle holder
4. Lower substrate

         Class B side feature creations are:

1.  Flange
2.  Heat stakes
3.  Locators
4.  Doghouse
5.  Push pin

CREATION OF SOLID PARTS:

  1.DOOR ARM REST: The arm rest is used to support the arm of a person travel in the car. The solid surface of door arm rest has a thickness of  2.5mm.There are multiple flanges created on B side of arm rest which is used to the connect to the lower substrate through Heat stakes.The Tooling axis also created for the draft analysis.The image of solid part and draft analysis are given below,

     

2.MAP POCKET: The solid body of map pocket is placed between lower substrate and bottle holder with a thickness of 2.5mm.And the flanges is created at top and bottom of it and connects to the lower substrate.The draft analysis also created with the reference of tooling axis.The images are given below,

3.BOTTLE HOLDER: The Bottle holder is used to keep the water bottle of the passenger.The Bottle holder is placed between the lower substrate and map pocket.It's thickness has created of 2.5mm.And B side feature flanges also created to connect with lower substrate by using heat stakes and ribs.And draft analysis also created with reference to tooling axis.The solid part and draft analysis images are given below,

     

4.LOWER SUBSTRATE: The lower substrate is the biggest part which connects the Arm rest, Map pocket, Bottle holder by using the Heat stakes, Ribs in the B side surface and Dog house also created which used to fit in the push pin.The lower substrate is mainly used to attach the electronic components like audio speakers,small subwoofer, Logo projecter lamp and Red lamp which used in the latest version cars, to attract the customers and for their safety in night time while opening the door it is used to Beware the rear side arriving passenger vehicles to avoid collision with the person who standing near the side door.The images of solid part and draft analysis given below,

CREATION OF B SIDE FEATURES:

       1.FLANGES: The design of flanges is to extend and increase the surface height so that it can connect with the other surface easily.The thickness of flange same as the thickness of main solid component.And also the flange contains the hole of 8mm, then draft angle has created of 0.5* Degree.The image of flanges are given below,

 

     2.HEAT STAKES:

              Heat stakes are used to join the parts together permanently like rivet connection with the help of flange for the better support and hinged feature but parts are more required for fixing the feature.so the heat stakes and flange connects which gives the proper fix.Then Rib is created to support the counter part of flange.The each heat stakes should placed at a distance of 55-60 mm. The drawing of heat stakes and solid part given below,

                 

   3.LOCATORS:

            The four way locater is used fit components before heat stakes fixed.It has 4 degrees of freedom along 2-axis.

                      

4.DOGHOUSE: 

          The dog house is used to give proper extension and prevent from sink marks.A sink mark cut is placed in the bottom of the dog house to protect.It can also be used for providing an minimal protection and design allocation.The reference drawing and solid body design of dog house is given below,

           

5.PUSH PIN:

         The push pins are used to fit the door trim from sheet metal door panel.the push pin image is given below,

    

The assembled solid parts images are given below,

  

CONCLUSION:

          The final conclution for designing the door trim is to generate a proper door structure of door which can be attached in every condition.The major objective behind the proper designing of the door trim body is to develop proper door which is cost effective and the strength is at considerable amount and can withstand every possible crash and dent situation.The secondary objective for this door trim panel design is to provide a luxury design which the customer feels comfort and satisfaction.