Challenge

Week 11 - Final project

UUmar Sha23 Jan 2023

AIM:

To create a door interior part from the inputs of class A surface along with master section by following the design rules followed in tier 1 and OEM industries in CATIA v5.

SOFTWARE USED:

CATIA V5

OBJECTIVES:

a) Creation of side door trim panle from given class A surface . Apply thickness to it and use attachment features .

b) Creation of flanges and heat stakes from given master sections .

c) Creation of dog house and various attachment features using industry standards

d) Performing draft analysis and ensuring the features and surfaces clear it .

INPUT OF CLASS A SURFACE:

Introduction :

The ten stages in automotive product life cycle developement are listed below .

1)Concept sketch

2) Styling class A

3)Feasilbility check

4)Concept validation

5)New product design

6)Product developement

7) Prototyping

8)Design validation

9)Pilot production

10)Mass production

From the above stages , it isin stage 5 that new product is developed and validated from class A surface . The objective is to design class B and class C surface from given class A surface and create a solid body from it using softwares like CATIA V5, solidworks or solidedge taking into consideration the draft analysis which makes the component suitable for production using injection molding process .

Given below is the procedure to create a new plastic component from given class A surface .

1) Creation of tooling axis

2) Creation of class b surface

3) Creation of class C surface

4) Creation of closed body

5) Draft Analysis .

Draft analysis is done to ensure that the designed part is manufacturable based on the draft conditions applied. It is done to ensure the proper ejection of the component from dies(for metals) or molds(for plastics). The basic idea is to ensure that the tooling axis has to be created in such a wat that it has no parallel surface profiles of the component so that the ejection of the components can be ensured . Tooling axis is the axis along which cavity and core are closed and opened .

The main components of interior door panel of a car consists of the following parts .

1) Arm rest

2) Map pocket (Consists of upper and lower part)

3) Upper substrate (Not given in the current model)

4) Lower substrate .

Rear side of the class A with master section

Create a product file and copy each component into different part files and name the accordingly .

Creation of Tooling axis for Arm Rest

Procedure for tooling axis creation

Step 1: Insert a geometrical set . Extract the base surface and create a point at its center using point on surface option from point tool. Look for suitable axis to create a tooling axis so that all faces clear tooling .

Step 2: Create an axis system without current option ticked at the above point. Create a position sketch with zy plane from axis system and above point as reference point.

Step 3: Use intersect 3d objects option from project tool to create 2 lines by selecting a suitable plane(zy). Now create 2 lines which coincide with lines on both sides of the projection point . Create a line using bisect option .Allign the line in required axis direction.This is our Y tooling axis .

Procedure to check for Draft analysis

1)Once the tooling axis is created , publish it and the component using Publication from tool option .

2)Insert Feature draft analysis option from insert tool bar

3) Change the view option to customize view parameters and click on material option under shading .

4) Now click on the axis option from Draft analysis tools , allign it with tooling axis and click on lock option to lock it .

5) Change draft angle value to 3 degree . Click on quick analysis mode to display feature according to given color scale . Check from all views to ensure the draft analysis is cleared .

6) Since the created tooling axis does not clear the draft analysis at the created axis , click on the lock axis button to unlock it . Now rotate the tooling axis by left clicking on the top round portion of the axis system . Rotate the axis till maximum clearance is obtained . Now right click on the axis and click lock current axis .

7) Create a line using the initial axis origin and this axis using point and direction (using compass direction) option . This is our required tooling axis .

8) Now if we check for draft analysis, we can observe that the ribbed area has not yet cleared draft analyisis. Hence we need to create a side core tooling axis . To do this , create a line using point and direction option with Y direction .

9) Repeat steps 1 to 5 to ensure the remaing portion which was not cleared using Tooling axis has been cleared using this axis .