Challenge

Week 11 - Final project

SSabhavath Eswar Naik27 Jan 2023

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 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.

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.

DESIGN METHODOLOGY OF DOOR TRIM PANEL :-

PROCEDURE OF DOOR TRIM PANEL :-

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

Door Arm Rest.
Lower substrate.
Outer Map Pocket.
Inner Map Pocket.

1) 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.

Updated Class A Surafce:-

Step 2:-

Tooling axis: -

First we extract the lower surface than using point on surface at 0mm create a point. The line has been created using line command. The point direction command is used for create the line (Tooling Axis) along z direction.

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 at 2.5mm distance.
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.

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)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 Map Pocket :-

D) Battle Holder:-

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.

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.

Step 4:-

Class-B Surface Creation :-

The creation of class-B surface can be done by smiply offsetting the class-A surface to the 2.5mm 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 Battle Holder :-

PUSH PIN:-

Push pin which helps us locating and arresting component of an assembly and it provides alignment in matting parts and also acts as various guide of mechanism.

Creation of Engineering Process:-

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.

Design Rules of Rib:-

Draft: 0.5 deg per side (minimum), but this value should not be high enough that it will cause

failure for other considerations. For example, more draft will result in less thickness at the top surface.

Thickness of ribs: 40% of wall thickness or 0.4*t where t is the wall thickness.
Height: ≤ 5 times the wall thickness i.e., 5*t.
Spacing (for more than 1 rib): 3:1- steel height/width ratio (maximum). h/w =3or2(preferred)

where h is the height of the rib and ‘W’ is the space between two ribs.

Minimum thickness at the tip: 0.75
Radius: 0.25mm max.
Ribs on the opposite side of the wall should be offset.
Ribs should be connected to other structural features where possible.
Rib root thickness should not be more than 30% of the wall thickness.

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.

Design Rules Of Dog House:-

Minimum height: Less than 6mm causes steel condition.
3:1 ratio of steel width to height. But 2:1 is preferred.
Minimum width: 3:1 ratio of steel width to height. But 2:1 is preferred.
Draft: minimum 1.5deg.
Sink saver: height (C) = 40% of nominal thickness. Width (B) = 3.0mm-6.0mm.
Optimal radius:25mm

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.

Resons For Heat Staking:-

Multiple staking shapes for different benefits.
Excellent durability
No extra materials are needed
Increased efficiency
Easy maintenance.

CREATION OF SOME ENGINEERING FEATURE:-

DOOR ARM REST:-

Bottle Holder:-

Lower Substrarte:-

Map Pocket:-

Some Iso-Constrained Sketches For Flanges:-

Door Arm Rest Flange Sketches With Sketch Solving Status:-

Flange surface:-

Map Pocket Flange Sketch With Sketch Solving Status:-

Bottle Holder Sketches With Sketch Solving Status:-

Heat Stake Sketches With Sketch Solving Status:-

Dog House Sketches With Sketch Solving Status:-

DRAFT ANALYSIS OF B Side COMPONENTS:-

With side core axis:-

Dog House Draft Analysis:-

DOG HOUSE WITH SIDE CORE AXIS DRAFT ANALYSIS:-

Heat Stake Draft Analysis:-

Four Way Locator Draft Analysis:-

Map Pocket Drafe Analysis:-

Bottle Holder Draft Analysis:-

Door Trim Assembly B Side Sraft Analysis:-

Assembly:-

The component is created in separated part files and then inserted into the assembly file. The component is assembled to their working positions by applying assembly constraint to them. Fix the 1^st component (LOWER SUBSTRACT) and inserted one by one. Inserted 3 push pin and use constraint to attach them with dog house.