Week 11 - Final project

REPORT ON DEVOLOPMENT OF DOOR TRIM PANEL CREATION USING THE INPUTS

DEVELOPMENT OF DOOR TRIM PANEL

Automotive Plastic Trim:

The design of Automotive Interior and Exterior plastic components is called Trims. The plastic components that you see inside the car are Interior. Ex: Dashboard, Instrument Panel, Doors, seating, and pillars. Plastic components that you see outside of a car are Exterior. ex: bumper, light assembly, hoods. 

Door Trim:

The door panel covers internal parts like the window regulator, the power window motor, and the wiring. It is attached to the sheet metal part of the door. It is designed differently based on the design of the sheet metal part of the door. Besides its aesthetic look, it also has many functional features attached to it such as an armrest, bottle holder, speaker attachment, etc. In older cars, door panels used to be made out of cardboard and upholstered with material that matches the rest of the upholstery within the cabin. On the other hand, most modern cars have door panels made from plastic. The main materials used include kenaf, which grows year-round and has excellent CO2 absorbing properties, and plant-derived plastic, making them environmentally friendly as well.

 

                                                                                                                                       

Aim:

To Design a Car door Plastic components placed in the car door panel by following the design standards used in the Industries. The Reference Designs for the Mechanical designing team of the Plastic components are drawn initially by the Class A surface defined by the Concept Sketch team as well as by the Styling Class A using Alias software and about Class A, the Part Body with thickness is designed by the Designing Team.

Abstract:

The project report deals with the steps and procedures followed while developing plastic trims for cars door from a class A surface provided, using CATIA V5 surface workbench. It explains the method I followed for creating the main tooling axis, side core axes, Class B surface, Class C surface, and final closed body creations. It also explains the draft analysis performed to check the manufacturability of the products using injection moulding. Various plastic door trims such as map pockets, armrest, a lower substrate, etc were successfully developed in this project.

Problem Statement:

• Create a closed body of the door trim panel using the Class A surface provided along with the master section.
• Create a push pin with the dog house for the lower substrate.
• Use Heat Stakes for the part to the part attachment. 

Tools Used:

Part workbench:close surface ,thicken surface ,pad ,pocket ,boolean opperations (add ,union trim ,remove ),draft ,edge fillet ,split command ,translate 

Surface Workbench:extrude ,extrapolate ,join ,parallel curve ,intersect ,boundry,multiple extract,extract ,curve smooth ,untrim ,project curve ,split ,trim,wireframe tools (line ,point ,plane ),sweep,multisection solid ,offset ,extrude

Given:

Class A Surface:

In the Automotive industry, there will be a dedicated team who will perform the aesthetic designing of various components including the whole vehicle. They will create various concept sketches after ideation. After that, they will also create a Class A surface of the product. This class A surface is then passed over to the NPD CAD team. They will initially inspect the Class A surface in order to check if the design is manufacturable or if it is following the engineering principles. If there are any issues with the design, they will contact the product design team and will ask to modify the Class A surface in order to solve the problem. Here I received the Class-A surface as shown below. 

                                        

 FRONT VIEW                                                                                                                        BACK VIEW

Map Pocket:

              

Arm Rest:

                    

Lower Substrate:

                                        

Bottle Holder :

                                

  

Master Sections:

These are the guidelines provided to a design engineer which describe how a component would/must look like once it is modeled into a solid component from the class-A surface. For example, in this model, we have received a master-section as an input which tells us about the thickness of the component and dimensions & type of the engineering features on the component.

                               

The Sequence of Operation:

1. Creation of Tooling Axis and Draft analysis for A-surface.
2. Creating B&C surface and Draft Analysis.
3. Creating attachment feature on B-Side and Draft Analysis.

CREATION OF TOOLING AXIS AND DRAFT ANALYSIS FOR A SURFACE 

MAP POCKET:

Tooling axis creation :

• Initially checked the class a surface whether boundry is correctly defined or not 
• extracted a surface through which max boundry is visible 
• created a point on the surface 
• created a line using the point and normal to surface method

                                                                             

draft analysis :

ckecked with the draft analysis using the tooling axis created with 3 degree draft 

                                   

LOWER SUBSTRATE :

TOOLING AXIS CREATION :

• CREATED A TOOLING AXIS USING POINT TO DIRECTION METHOD .
• CREATED A POINT ON CURVE 
• CREATED A LINE USING THE POINT AS INPUT IN POINT TO DIRECTION METHOD 

                                                                          

DRAFT ANALYSIS:

ckecked with the draft analysis using the tooling axis created with 3 degree draft 

                               

BOTTLE HOLDER :

TOOLING AXIS CREATION :

• Initially checked the class a surface whether boundry is correctly defined or not 
• extracted a surface through which max boundry is visible 
• created a point on the surface 
• created a line using the point and normal to surface method

                                             

DRAFT ANALYSIS:

ckecked with the draft analysis using the tooling axis created with 3 degree draft 

            

few areas and surface s are not getting cleared because of less draft angle in the class a surface so some alternations need to be done on the class a surface 

ARM REST:

Arm rest class a surface doent have proper boundry so worked on those aeras to get proper boundry 

                                         

TOOLING AXIS CREATION :

• CREATED A TOOLING AXIS USING POINT TO DIRECTION METHOD .
• CREATED A POINT ON CURVE 
• CREATED A LINE USING THE POINT AS INPUT IN POINT TO DIRECTION METHOD 
• HENCE THERE ARE ADDITIONAL SURFACE WHICH CANNOT BE CLEARED USING THE MAIN TOOLING AXIS
• CREATED A SIDE CORE AXIS BY TAKING INPUT FROM THE MAIN TOOLING AXIS AND POINT CREATED BY POINT TO DIRECTION METHOD 

                                          

MAIN TOOLING AXIS                                                                                               SIDE CORE AXIS 

DRAFT ANALYSIS:

ckecked with the draft analysis using the tooling axis created with 3 degree draft