Week 11 - Final project

Door Trim Final Project

ARM REST AREA

Class A surface:

Given Door arm rest area penel boundery check done open boundery in arm rest area so Immprove our Class A surface open boundery arrseted After check boundery this is perfect Improve Class A surface.

Tooling Axis:

On the surface method tooling direction checked this is my Tooling axis.

Draft Analayis:

Improve Class A surface some of area draft not Clear update given to Class A engineer. both C surface B surface Closed body also checkthis draft this also clear 2.9 draft degeree.

Side Core Axis:

Improve class a Surface onr time check with Side core Axis this Draft clear with 2.9 degerees.Engineering features flange created with respect Master section this is also draft clear with .45 degerees.

LOWER SUBTRECT AREA

Class A surface:

Given Lower subtract area boundey check not have any open this is Perfect Class A surface.

Tooling Axis:

ON the surface method extract the surface placed on the surface point fix draw the line Point and direction This line my Tooling axis.

Draft Analayis:

Check the draft analysis with respect to the tooling axis Clear Class A surface And C surface closed body Draft clear 2.9 degerees.Engineering features Locaters and Heat stakes also clear draft 0.45 degerees.

Side Core Axis:

Dog house Area draft clear with .45 degerees with respect to the Side core axis.

UPPER MAP BOCKET AREA

Class A surface :

Given class A surface boundery check this no open gap this is perfect Class A surface

Tooling Axis:

Take the flat surface darw the line Point and direction method this is My tooling axis.

Draft Analayis:

check the draft analayis with respect to the tooling Axis draft clear Class A surface and C surface and closed body clear 2.9 degerees. Engineering features Flange also clear 0.45 degerees.

BOTTLE HOLDER AREA

Class A surface:

Given Class A surface boundery check not have open gap This my class a surface.

Tooling Axis:

Extract the Flat surface draw the line point and direction mothed Draw the line this line My tooling Axis.

Draft Analayis:

Check the Draft analayis with respect to the tooling axis Class A surface not clear the Draft analayis update given to the Class A engineer. Closed surface also have some issue Draft not clear Some area. But engineering features Flanges clear with 0.45 Draft degeress.

Attachment features:

DOGHOUSE:

Doghouse is an engineering feature used in the plastic trim design which helps to remove sink marks formed on Class-A surface while creating attachment feature on Class-B surface. Doghouse is a supporting feature, other features like locators, heat stakes, pushpins are mounted on top of doghouse for fixing and assembly purpose. Doghouses are subjected to draft analysis to prevent breakage of the component during ejection from the mould.

Flanges :

Flanges are the joining features that help to assemble different components. The mastersection was used to make flanges. After creating one flange axis to axis sytem was used to translate the flanges. The draft of 0.5 is given to the flanges. The gap between flanges should be 60-100 mm. Boolean operations were used to add attachment features into closed body.

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. This reforming can be used in a wide variety of applications.

Applications range from staking plastic bosses for assembly of car door panels to joining PCBs to plastic housings. Banefits of his technique includes; no vibration damage, no particulates, the ability to stake metalized coated application and the capability to stake in difficult to access or restricted areas.

The progressive melting of plastic under continuous pressure forms the head. When staking the right combinations of heat and pressure for the applications is critical.

The advantages of heat staking are as follows:

1. Simplications of the machinery
2. Reduced cost of machinery.
3. Multiple fastening point.
4. Allows higher density of welds compared to hot air, cold form or ultrasonic welding.

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.

The design rules of ribs

1. Rib thickness should be 0.4 times of thickness of the part.
2. The walls of rib should be drafted with 0.5 degrees draft.
3. Top height of ribs should be at least 5 times part thickness
4. Thickness of rib at tip should be equal or less than 0.75mm.
5. Maximun fillet vale should be 0.25mm Radius..