Week 11 - Final project
Designing and development of vehicle interior door trim using Catia V5 with provided class A surface along with Master section and also to create the engineering features as per design rules.
OBJECTIVE:
- To create thickened part using master section for reference.
- To create the mounting features as per design guidelines in the industry and with master sections.
- To perform Draft analysis & Tooling analysis.
Procedure for door trim :
The door panel is divided into four parts for ease of design. There are,
- Door Arm Rest
- Lower substrate
- Mapp pocket
- Bottle holder
A) 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.
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.
- Make a line along the Y axis through point on the surface and the line itself is the tooling axis.
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 formed while offsetting the class-A surface.
- First offset the class-A surface
- 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.
Step 7: Make the final trim to solid part using close surface.
Step 8: 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.
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 a line along -axis and itself is the 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.-
Step 7: Make the final trim to solid part using close surface.
Step 8: 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.
C)Mapp 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.
Step 7: Make the final trim to solid part using close surface.
Step 8: 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.
D) Bottle 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 a line along point on the srface and along Y axis and the line itself is the 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 simply 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.
Step 7: Make the final trim to solid part using close surface.
Step 8: 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.
Creation of Engineering Features to the Door Trim:
Dog house is an engineering feature used in plastic trim design. Dog houses are used as supporting feature. Sometimes other engineering features like snaps; locators etc. are mounded on them to increase their strength. Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from mould cavity. Dog house and other engineering components are built on B-surface
Step: 1
Creating the sketch by extracting the surface on the final joined surface By ofeseting plane to the surface by making a point over exctracted surface as reference for both sketch and plane.
Step: 2
Pad the sketch created and Draft the solid model at an angle of 3 degree and shell it with a inside wall thickness of 2.5mm.
Step: 3
Extract the surface of lower subrtrate and offset it to a height of 12mm and simultaneosly , using multiple extract command , extract the inside wall of dog house and off set it a 1.5mm outward and trim it.
Step: 4
Using split command , slit the created surface to obtain a shell type enclosure and using body split, split the Main dog house body with surface.
Step: 5
Create a sketch of rib and pad and make sketch on the roof of the dog house for pin clearance and split, and finally unitrim it with lower substrate.
Creating the Heat Stake:
Heat staking is a pulsed – heat process to join two or more parts out of which one at least is made of plastic . The plastic is to deform the plastic material using the heat and foam at a set process time. The bond is made by partially de forming the plastic part in order to fix the other. Heat stakes makes it easily to bond metal to plastic is commonly used in high volume and low cost application such as Automotive, IT and consumer appliances.
Step: 1
Creating the sketch by extracting the class A surface, by each surfaces separately, point and axis system created simultaneously on the surface. Using positioned sketch.
Step: 2
The sketch feature is then extracted to the required dimension. And it is drafted for the 0.5 deg to the sliding tooling axis, it is filleted for radius 0.25 of smooth edges as shown below.
The support rib as created, where the flange will come and sits to get arrested to the heat stake.