Week 11 - Final project
AIM- To design and development of vehicle interior door trim using given class A surface along with master section. Also create the side attachment features as per design rules.
OBJECTIVE-
- To create the thickened part using master section for reference.
- To Create the mounting features are per design rules in the industry and with master sections.
- To creating tooling axis and perform draft analysis.
INTRODUCTION-The door panel is the interference between the interior of the car and the inner workings of the door. Generally, the door panel is divided into two parts of easy designing like arm rest, map pocket, lower substrate, bottle holder, these requires one of the toughest requirements among the interior parts of the car. This should be designed to with stand the load while being less than 2mm in the thickness and also protect the occupants during collisions. Door currently has an inner full width panel consisting of electronic windows. Central locking system and speakers. These panels typically consist of a covered with either textiles or plastics.
A surface:A surface is the styling surface that is visible to the consumer and gives an aesthetic look for the model designed. Surfaces which are having curvature continuity is also called Class A Surface. Engineering features are not added to this surface. Class A is any of set freedom surface high efficiency and quality. Although strictly it is nothing more than surface have curvature and tangency alignment.
B Surface:Class B surfaces are the secondary surfaces that you can see sometimes includes all the engineering features such as dog house, locators, ribs, flanges, etc. This surface is the direct offset of the Class A surface which gives thickness to the component.
C Surface:This surface is the combination of the Class A and Class B surfaces also they are the backside surfaces that can have tool marks, flash, and other imperfections without hurting appearance, function, etc.
Engneering Features
After creating the closed body some engineering features are created like Ribs,Dog House,Heat Stakes,Flanges.
FLANGE: Flange are needed to join different component together, so I have to create flange as design guidelines of master section given as the input basically the measurement and location of the flange.
RIBS: Ribs provide a means to economical stiffness and strength in molded parts without increasing overall wall thickness. They also facilitate:
1) Locating & arresting components of an assembly.
2) Providing alignment in mating parts.
3) Acting as stops or guides for mechanisms.
DOG HOUSE: Dog house is an engineering feature used in plastic trim design. The primary function of a dog house is to avoid sink marks on the class A surface which may occur due to features such as a thick screw boss or rib on the backside of Class A. So, the best possible solution is to increase the height and decrease the cross-sectional thickness of the ‘legs’ by using a dog house. We can also use them for solving the necessity of large length features such as a screw boss which may require a large length sometimes. We can use a dog house and make a screw boss above it in such situations. We can also use them for making features that are perpendicular to the main tooling direction.
HEAT STAKES
Manufacturing operations currently use many different combinations of attachment methods to keep components together. Common fasteners such as bolts, screw, and rivets can be used to form permanent attachments, but there are attachment methods that don’t require secondary hardware. One of those methods is heat staking which does not require additional fasteners.
Heat staking is the process to attach two separate component together secondary component. It’s a permanent attachment method that doesn’t require any additional material such as adhesive or a solvent to make the permanent bond. The only addition is the heat applied to melt the plastic and tool to shape the plastic to form the mechanical connection.
Heat staking is a great option that is comparable in strength and durability to other operations involving secondary fasteners without extra cost. These connections can also resist corrosion in harsh environments.
REASONS FOR HEAT STAKING-
- Multiple staking shapes for different benefits.
- Excellent durability
- No extra materials are needed
- Increased efficiency
- Easy maintenance.
Class A of inner map pocket
For the given class A surface tooling axis is created exracting the surface with no propogation and a normal line is created to the extracted surface at a point which is created on the extraced surface.
Draft Analysis
- Final plastic parts are the nominal draft angle is 3 degrees but even 7degree is allowed for the subassemblies like ribs and slots.
- Insert< Analysis< Feature draft analysis
- First the compass is moved to the part which used to define the tooling axis new current draft direction then lock the draft direction using the lock icon.
- The color of the chart indicates the draft if the color is indicated that means the part passes and used for further operation.
- By using the analysis under the running point icon, we can check draft angle at the various surface of the component.
- If the surface satisfied the draft angle, then it shows the green color if not appears in red color.
by using these steps we can observe the draft analysis of a component, here we can observe the draft analysis of a class A surface
Creation of Class B surface
Class B surface has been created by offsetting of class A surface. Offsetting has been done using offset class A 2.5mm distance.
Creation of Class C surface
Using the multiple extract commands boundaries of class, A surface were extracted. Class C surface joins class A and Class B surfaces. It is created using the sweep command. Inputs for the sweep were extracted boundary, class a surface angle values and length of the sweep. Due to surface irregularities, it was not possible to make a single sweep. Hence several sweep and multi section were created, and finally they joined together to create a Class C surface.
Final closed body
By Joining the class c with class A, And trimmed with class b surface we get the closed surface.
Creation of Flanges
Creation of Heat Stakes
Creation of Ribs
Final body with engineering features
Draft Analysis of body
Class A of Bottle Holder
For the given class A surface tooling axis is created exracting the surface with no propogation and a normal line is created to the extracted surface at a point which is created on the extraced surface.
Draft Analysis of Class A
Some area of Class A surface is in red with small draft angle of 1.8 and 1.3
Creation of Class B Surface
Class B surface has been created by offsetting of class A surface. Offsetting has been done using offset class A 2.5mm distance.
Creation of Class C Surface
Using the multiple extract commands boundaries of class, A surface were extracted. Class C surface joins class A and Class B surfaces. It is created using the sweep command. Inputs for the sweep were extracted boundary, class a surface angle values and length of the sweep. Due to surface irregularities, it was not possible to make a single sweep. Hence several sweep and multi section were created, and finally they joined together to create a Class C surface.
Final Closed Body
By Joining the class c with class A, And trimmed with class b surface we get the closed surface
Creation of Flanges
Final Body with Engineering Features
Draft Analysis of Final Body
Class A Surface of Arm Rest
Given surface is a outer surface which is soft layer for the comfort of user so offset of 2mm is taken and the obtained surface is resolved and used as Class A surface. For the given class A surface tooling axis is created exracting the surface with no propogation and a normal line is created to the extracted surface at a point which is created on the extraced surface.
Draft Analysis of modified Class A
Creation of Class B surface
Class B surface has been created by offsetting of class A surface. Offsetting has been done using offset class A 2.5mm distance.
Creation of Class C surface
Using the multiple extract commands boundaries of class, A surface were extracted. Class C surface joins class A and Class B surfaces. It is created using the sweep command. Inputs for the sweep were extracted boundary, class a surface angle values and length of the sweep. Due to surface irregularities, it was not possible to make a single sweep. Hence several sweep and multi section were created, and finally they joined together to create a Class C surface.
Final Closed Body
By Joining the class c with class A, And trimmed with class b surface we get the closed surface
Creation of Flanges
Final Body with Engineering Features
Draft Analysis of Arm Rest
Class A Surface of Lower Door Trim
For the given class A surface tooling axis is created exracting the surface with no propogation and a normal line is created to the extracted surface at a point which is created on the extraced surface.
Draft Analysis of Class A
Creation of Class B surface
Class B surface has been created by offsetting of class A surface. Offsetting has been done using offset class A 2.5mm distance.
Creation of Class C Surface
Using the multiple extract commands boundaries of class, A surface were extracted. Class C surface joins class A and Class B surfaces. It is created using the sweep command. Inputs for the sweep were extracted boundary, class a surface angle values and length of the sweep. Due to surface irregularities, it was not possible to make a single sweep. Hence several sweep and multi section were created, and finally they joined together to create a Class C surface.
Final Closed Body
By Joining the class c with class A, And trimmed with class b surface we get the closed surface
Creation of Engineering Features
Final Body with Engineering Features
Draft Analysis of Door Trim
Draft analysis at Ribs is in blue with minimum draft angle
Draft Analysis of Dog House
Draft Analysis of Dog House by side core axis
Final Assembly of Side Door Trim
CONCLUSION
The door panel successfully designed by following all design rules used in automotive industry. All the attachment feature are properly placed at different location.