Week 11 - Final project

AIM: To design the car door inner panel with reference to given Class-A surface by using given mastersection, creating attachment features and performing draft analysis to check the manufacturing feasibility of the component by using software CATIA V5.

Methodology:

The methodology of the project is explained here:
1. Class-A suface was extracted from the given surface.
2. Tooling Axis were created of the individual component.
3. Class-B and Class-C surface were created with the OEM guidelines.
4. Formed Solid body from the closed surface.
5. Engineering features were created for attachment.
6. Draft analyses of each component was performed to check the manufacturing feasibility.

The manufacuring Process of plastic door panel is called Injection molding. In this manufacturing process the heated molten plastic material is injected into the mould between core and cavity and cooled down to form a solid plastic component.

Draft Analysis 

It is performed to check the manufacturing feasibilty of a component. 

TOOLING AXIS: The tooling axis is defined as the direction in which the mold or core and cavity opens is the tooling axis.

PROCEDURE 

Given CLASS-A surface with Mastersection

1. Lower substrate
2. Map pocket
3. Bottle holder
4. Armrest

LOWER SUBSTRATE

Class-A surface of Lower substrate.

Draft Analysis on Class-A surface with 3 degrees along Tooling Direction

Class-B surface offset at 2.5 mm from class-A

Class-C surface swept from Class-A boundary with 3 degrees draft in tooling direction

A+C SURFACE

CLOSE VOLUME TRIM AC SURFACE WITH B SURFACE

PART BODY OF LOWER SUBSTRATE

DRAFT ANALYSIS ON PART BODY

Map Pocket Class-A surface Draft analysis along with Tooling Direction

B SURFACE CREATION

C SURFACE CREATION WITH A SURFACE BOUNDARY

JOIN A+C SURFACE

PART BODY OF MAP POCKET

BOTTLE HOLDER

Draft Analysis performed on Class-A surface along Tooling Direction

CRATION OF B SURFACE

C SURFACE CREATION

A+C SURFACE CREATION

FINAL TRIM WITH B SURFACE

PART BODY OF BOTTOLE HOLDER

DRAFT ANALYSIS ON PART BODY

SIDE CORE AXIS DRAFT ANALYSIS

ARMREST

Draft Analysis of Class-A surface 

SIDE CORE AXIS DRAFT ANALYSIS

FINAL B SURFACE CREATION

C SURFACE CREATION

ARMREST CLOSE VOLUME

PART BODY OF ARMREST

ATTACHEMENT FEATURE CREATION 

DOG HOUSE

Doghouse is a supporting feature pushpins are mounted on top of doghouse for fixing and assembly purpose.

PUSH PINS- Push pins are used for joining one component to another . These are basically attached to the doghouse.

 FLANGE

 Flanges are the joining features that help to assemble different components.The gap between flanges should be 60-100 mm.

HEAT STAKE

HEAT STAKES- Heat stakes also known as thermoplastic staking, it is process of joining two dissimilar materials together. In heat staking, local heating and cooling is used to raise the temperature of plastic components and allow plastic reforming to be carried out.

Ribs- Ribs are the feature that provides stiffness to the parts and toughness without increasing the thickness of the part.

Locators- Locators provide easy alignment to the parts which are mating with each other.

DRAFT ANALYSIS ON LOWER SUBSTRATE WITH ENGG.FEATURES

SIDE CORE AXIS FOR DOGHOUSE DRAFT ANALYSIS IS 0.5 DEGREE.

LOWER SUBSTRATE  WITH ALL FEATURE

MAP POCKET DRAFT ANALYSIS WITH ENGG. FEATURES

DRAFT ANALYSIS ON BOTTOLE HOLDER WITH FEATURES

BOTTOLE HOLDER WITH FEATURES

ARMREST WITH ENGG.FEATURE DRAFT ANALYSIS WITH LIFTER AXIS

CORE SIDE AXIS DRAFT ANALYSIS

ARMREST WITH FEATURE

PARTING LINE IN MAP POCKET 

• A ‘parting line’ is the line of separation on the plastic part where the two halves of the plastic injection mold meet. The line actually indicates the parting ‘plane’ that passes through the part.

FINAL DOOR TRIM PANEL WITH ALL FEATURE