Week 11 - Final project
Aim : To create a CAD model of a side door trim panel from given class A surface .
Objective:
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 .
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 .
Step by step procedure
1) Creation of tooling axis
To create tooling axis , we must import the model into catia as a product .
File=>open=>browse=> MASTER SECTION DEVELOPEMENT.igs file .
Given class A surface
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 .
First of all I have master section with Arm rest :
Creation of Tooling axis for Arm Rest
use dart analysis for check tooling axis
tooling axis is not clear whole surface then create another side tooling axis for clearing draft
check darft analysis
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) Repeat steps 1 to 5 to ensure the remaing portion which was not cleared using Tooling axis has been cleared using this axis .
TOOLING AXIS FOR LOWER SUBSTATE
DARFT ANALYSIS
TOOLING AXIS FOR MAP POCKET
CREATE DRAFT ANALYSIS
TOOLING AXIS FOR BOTTLE HOLDER
CREATE DRAFT ANALYSIS
Here we can observe that regions in blue colour has a 0 degree draft angle . This would lead to ejection problems while molding process . Hence the class A surface has to be modified to meet draft requirements Hence we have created tooling axis for all components .
2) Creation of class B surface
Procedure to create class B surface for ARM REST .
Step 1: Use offset tool with a distance value of 2.5mm to create offset of class A surface .
Step 2: After offsetting , extrapolate tool was used to extend all the edges of this surface . This is done to ensure that the parting line comes at B surface .
Step 3: In areas where extrapolate was not possible (Fillet or cusped surfaces) multisection surface option was used .
Step 4: Join all the extrapolated surface and multi section surfaces to obtain a single surface .
Hence the class B surface was created for ARM REST.
Similarly , class B surface was created for other components .
Create class B surface for LOWER SUBSTATE:
Create class B surface for MAP POCKET:
Create class B surface for BOTTLE HOLDER:
3) Creation of Class C surface
Procedure for creation of class C surface for ARM REST
Step 1: Use sweep command to create a new surface an an angle with respect to a surface . This angle is dependant on draft angle for free edges and ususally 90 degree for mating surfaces.
Step 2: In areas where sweep is not possible , use Multi section surface to create a new surface .
Step 3: Join all surfaces to obtain C surface.
Use trim or join option to join Class A and Class C
Hence JOIN CLASS A & CLASS C surface was obtained for ARM REST
Similarly C surfaces were obtained for all other components .
C surface for LOWER SUBSTATE .
C surface for MAP POCKET.
C surface for BOTTLE HOLDER.
4) Creation of closed body
Procedure for creation of closed body for ARM REST.
Step 1: Use trim option to join Class AC and Class B .
Hence we have obtained closed body .
Similarly closed body was obtained for all other parts
Closed body for LOWER SUBSTATE
Closed body for MAP POCKET
Closed body for BOLLTE HOLDER
5) Draft Analysis
Procedure to check Draft analysis for Lower substrate .
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 om 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 . Click ok to complete the Draft analysis mode.
DRAFT ANALYSIS FOR ARM REST
DRAFT ANALYSIS FOR LOWER SUBSTATE
DRAFT ANALYSIS FOR MAP POCKET
Engineering feature creation for arm rest
FINAL MASTER SECTION
