Week 11 - Final project
Introduction
To design and develop CAD model of front door trim panel considering following inputs as like in OEM and tier1 companies. Let's speak about what is front door trim panel, which is aesthetic for interior look with all comfortable features like arm rest, bottle holder, widow control unit, etc. It's a plastic part/product which is manufactured by injection molding. Here the given CLASS A SURFACE with MASTER SECTION is shown in figure 1.
Given CLASS A SURFACE with MASTER SECTION
Given PUSH PIN part file
By the uses of input need to design and develop by following steps:
- TOOLING AXIS
- CLASS B SURFACE
- CLASS C SURFACE
- CLOSED SURFACE
- PART BODY
- ENGINEERING FEATURES like Flange, Ribs, Heat stakes, Loactors and Dog House
- DRAFT ANALYSIS
- ASSEMBLY
Product and Part files
Here i separated CLASS A SURFACE and MASTER SECTION because the trim parts of the front door panel will manufactured in many parts and assemble it as single product by the process plastic welding. Plastic welding is a joining process of the two plastic material in a product with the uses of heat stakes and flanges of the part.
Separated CLASS A SURFACE and MASTER SECTION with different color
Design Metrology
ARM REST
Given CLASS A SURFACE with MASTER SECTION
Tooling Axis
Here i created two tooling axis because this plastic component can't create by using single tooling axis due to complex shape.
The Way of Creating the Tooling Axis for X-AXIS of the Component
Need to take center of the surface for a Tooling axis. So, here i took the bottom face which is meet at all surface in a single point which is easy to create a tooling axis and i extracted that face by using extract command(extract definition = surface) as shown in figure 2.
By the uses of that face i created center point with the help of point command(Point definition = on surface = distance + reference) as shown in figure 3.
Then i created a line on the point with the help of line command(line definition = normal to surface = surface + point) as shown in firgure 4 which is showing in orange color.
Thus the way i created Tooling Axis for draft analysis as shown in figure 5 which is showing in yellow color center line.
Tooling Axis for X-Axis/Normal Tooling Axis
The Way of Creating the Tooling Axis for Y-AXIS of the Component
Need to create a another tooling axis for Y-axis/side core axis to clear some surface because of side core. So, here i took the same point which is help to create a line for normal tooling axis. By the uses of that point i created a line on the point with the help of line command(line definition = point-direction = point + Direction(Y-axis)) which is showing in orange color as shown in firgure 6.
Thus the way i created Tooling Axis on Y-axis for draft analysis as shown in figure 7 which is showing in pink color center line.
Tooling Axis for Y-Axis/Side Core Axis
CLASS B SURFACE
To create a CLASS B SURFACE need to offset CLASS A SURFACE into 4.5mm because we have kushan which is cover the plastic part according to the master section and also need to offset CLASS A SURFACE into 2mm for plastic part CLASS A SURFACE.
CLASS C SURFACE
CLOSED SURFACE
Well creating closed surface i need join CLASS A SURFACE with CLASS C SURFACE by using join command, then i can trim joined surface(CLASS A SURFACE + CLASS C SURFACE) with CLASS B SURFACE.
Flange
According to the master section the flange has been created as shown in figure 8.
Draft Analysis
Draft Analysis is used to analyze whether our part model created in CAD is manufacturable based on the draft condition applied.
Color scale variant with draft angle for CLASS A SURFACE/Final Component as a Normal tooling axis
Color scale variant with draft angle for CLASS A SURFACE/Final Component as a Side core axis
CLASS A SURFACE/Final Component for Normal tooling axis
CLASS A SURFACE/Final Component for Side core axis
Final part model design with the proper color code of the draft analysis on X-Axis
This draft analysis is the normal tooling axis towards to cavity of the final component.
Final part model design with the proper color code of the draft analysis on Y-Axis/side core axis
This draft analysis is the side core axis towards to side core of the final component.
Final part model in various orientations for ARM REST
LOWER SUBSTRATE
Given CLASS A SURFACE with MASTER SECTION
Tooling Axis
Here i created two tooling axis because this plastic component can't create by using single tooling axis due to complex shape. One axis for normal tooling axis to the plastic component and another one axis for side core axis to manufactue dog house.
The Way of Creating the Tooling Axis for Y-AXIS of the Component
Need to take center of the surface for a Tooling axis. So, here i took the two points at the CLASS A SURFACE which is easy to access center point of the CLASS A SURFACE by using point command(point definition = point 1 + point 2 + ratio(0.5)) as shown in figure 9.
Then i created a line on the point with the help of line command(line definition = point-direction = point + direction(Y-axis)) as shown in firgure 10 which is showing in orange color.
Thus the way i created Tooling Axis for draft analysis as shown in figure 11 which is showing in yellow color center line.
Tooling Axis for Y-Axis/Normal Tooling Axis
The Way of Creating the Tooling Axis for Z-AXIS of the Component
Need to create a another tooling axis for Z-axis/side core axis for dog house. So, here i took the same point which is help to create a line for normal tooling axis. By the uses of that point i created a line on the point with the help of line command(line definition = point-direction = point + Direction(Z-axis)) which is showing in orange color as shown in firgure 12.
Thus the way i created Tooling Axis on Y-axis for draft analysis as shown in figure 13 which is showing in pink color center line.
Tooling Axis for Z-Axis/Side Core Axis
CLASS B SURFACE
To create a CLASS B SURFACE need to offset CLASS A SURFACE into 2.5mm.
CLASS C SURFACE
CLOSED SURFACE
Well creating closed surface i need join CLASS A SURFACE with CLASS C SURFACE by using join command, then need join that joined surface(CLASS A SURFACE + CLASS C SURFACE) with CLASS B SURFACE.
Engineering Features
Heat Stake
According to the master section the heat stakes has been created as shown in figure 14.
Locator
Uses of locator to locate the part and heat stake into perfect clearance in it position.
Dog House
Uses of dog house is too hold the push pin between plastic component and sheet metal of the front door.
Draft Analysis
Draft Analysis is used to analyze whether our part model created in CAD is manufacturable based on the draft condition applied.
Color scale variant with draft angle for CLASS A SURFACE/Final Component
Color scale variant with draft angle for Engineering features on Y-Axis
Heat Stake
Locator
Dog House
Color scale variant with draft angle for Dog House on Z-Axis
CLASS A SURFACE
Final part model design with the proper color code of the draft analysis on Y-Axis
This draft analysis is the normal tooling axis towards to cavity of the final component.
Draft Anaylsis at 3°
Draft Anaylsis at 0.5°
Final part model design with the proper color code of the draft analysis at 0.5° on Z-Axis/side core axis
This draft analysis is occur towards the tooling axis on x-axis/side core axis to make/analysis the dog house for manufacturing.
Final part model in various orientations of Lower Substrate
MAP POCKET
Given CLASS A SURFACE with MASTER SECTION
Tooling Axis
Here i created two tooling axis because this plastic component can't create by using single tooling axis due to complex shape. One axis for normal tooling axis to the plastic component and another one axis for side core axis to manufactue dog house.
The Way of Creating the Tooling Axis for Y-AXIS of the Component
Need to take center of the surface for a Tooling axis. So, here i took the base face which is meet at all surface in a single point which is easy to create a tooling axis and i extracted that face by using extract command(extract definition = surface) as shown in figure 15.
By the uses of that face i created center point with the help of point command(Point definition = on surface = distance + reference) as shown in figure 16.
Then i created a line on the point with the help of line command(line definition = point-direction = point + direction(Y-axis)) as shown in firgure 17 which is showing in orange color.
Thus the way i created Tooling Axis for draft analysis as shown in figure 18 which is showing in yellow color center line.
Tooling Axis for Y-Axis/Normal Tooling Axis
The Way of Creating the Tooling Axis for Z-AXIS of the Component
Need to create a another tooling axis for Z-axis/side core axis for dog house. So, here i took the same point which is help to create a line for normal tooling axis. By the uses of that point i created a line on the point with the help of line command(line definition = point-direction = point + Direction(Z-axis)) which is showing in orange color as shown in firgure 19.
Thus the way i created Tooling Axis on Y-axis for draft analysis as shown in figure 20 which is showing in pink color center line.
Tooling Axis for Z-Axis/Side Core Axis
CLASS B SURFACE
To create a CLASS B SURFACE need to offset CLASS A SURFACE into 2.5mm.
CLASS C SURFACE
CLOSED SURFACE
Well creating closed surface i need join CLASS A SURFACE with CLASS C SURFACE by using join command, then need join that joined surface(CLASS A SURFACE + CLASS C SURFACE) with CLASS B SURFACE.
Flange
According to the master section the flange has been created as shown in figure 21.
Engineering Features
Dog House
Uses of dog house is too hold the push pin between plastic component and sheet metal of the front door.
Draft Analysis
Draft Analysis is used to analyze whether our part model created in CAD is manufacturable based on the draft condition applied.
Color scale variant with draft angle for CLASS A SURFACE/Final Component
Color scale variant with draft angle for dog house on Y-Axis
Color scale variant with draft angle for Dog House on Z-Axis
CLASS A SURFACE
Final part model design with the proper color code of the draft analysis on Y-Axis
This draft analysis is the normal tooling axis towards to cavity of the final component.
Draft Anaylsis at 3°
Draft Anaylsis at 0.5°
Final part model design with the proper color code of the draft analysis at 0.5° on Z-Axis/side core axis
This draft analysis is occur towards the tooling axis on x-axis/side core axis to make/analysis the dog house for manufacturing.
Final part model in various orientations of MAP POCKET
BOTTLE HOLDER
Given CLASS A SURFACE
The Way of Creating the Tooling Axis
Need to take center of the surface for a Tooling axis. So, here i took the bottom face which is meet at all surface in a single point which is easy to create a tooling axis and i extracted that face by using extract command(extract definition = surface) as shown in figure 22.
By the uses of that face i created center point with the help of point command(Point definition = on surface = distance + reference) as shown in figure 23.
Then i created a line on the point with the help of line command(line definition = normal to surface = surface + point) as shown in firgure 24 which is showing in orange color.
Thus the way i created Tooling Axis for draft analysis as shown in figure 25 which is showing in yellow color center line.
Tooling Axis
CLASS B SURFACE
To create a CLASS B SURFACE need to offset CLASS A SURFACE into 2.5mm.
CLASS C SURFACE
CLOSED SURFACE
Well creating closed surface i need join CLASS A SURFACE with CLASS C SURFACE by using join command, then need join that joined surface(CLASS A SURFACE + CLASS C SURFACE) with CLASS B SURFACE.
Flange
Draft Analysis
Draft Analysis is used to analyze whether our part model created in CAD is manufacturable based on the draft condition applied.
Color scale variant with draft angle for CLASS A SURFACE/Final Component
CLASS A SURFACE
Final part model design with the proper color code of the draft analysis
Final part model in various orientations for BOTTLE HOLDER
Assembled all parts into a product
FINAL PRODUCT
Conclusion
The given CLASS A SURFACE with Master section for a product with parts has been designed and developed by CATIA V5.