Week 11 - Final project

* AIM

To create a door interior part from the inputs of class A surface along with master section by following the design rules followed in tier 1 and OEM industries in catia v5

* SOFTWARE USED

DASSAULT SYSTEMES CATIA V5

* OBJECTIVES

• Create a sketch by using Positioned sketch.
• All the sketches should be Iso-Constrained.
• Ensured Proper Tree Structure.
• Geometrical sets should having a proper name based on the sketches present inside of it.
• Create thickened part using master section for reference.
• Create the mounting features as per design guidelines in the industry and with master sections.
• Apply material details.
• Creating of Draft analysis & Tooling analysis.
• Creation of parting lines and check tooling feasibility.

* INPUT OF CLASS A SURFACE

Since the input class A surface is containing four different parts(class A). So class "B" and "C" for all the surface has been created in separate catpart. Also performing draft analysis and tooling axis separately. Finally all the surface have assembled together in one cat product.

The door panel is the interface between the interior of the car and the inner workings of the door. Generally the door panel is divided into parts for easy designing like arm rest, map pocket, lower substrate. These require one of the toughest requirement among the interior parts of the car. This should be designed to with stand the load while being less than 2mm in thickness and also to protect the occupants during collisions.

Door currently have an inner full width panel consisting of electronic windows, central locking system and speakers. These panels typically consists of a foamed core covered with either textiles or plastics.

* CREATION OF TOOLING AXIS – CLASS A SURFACE

TOOLING AXIS

The tooling direction is used to find the direction in which the part is removed from the core and cavity. The draft angle should be positive to the tooling axis to manufacture the component easily.

DRAFT ANLAYSIS

Draft analysis in catia is a command that is used to detect if the part you drafted will be easily removed from the mold. it is performed based on color ranges identifying zones on the analyzed element.

Most of the industries is using minimum draft angle is 3 degree

* CREATION OF CLASS B SURFACE

• Insert a new gemeotrical set.Measure the value of thickness in master section.The value is 2.5mm
• Offset the class A surface to 2.5mm.
• Check all the sub elements are formed if not try to fix it locally

LOWER SUBSTRATE CLASS B

BOTTLE HOLDER CLASS B

ARMREST CLASS B

MAP POCKET CLASS B

CREATION OF CLASS C SURFACE

• Analyse the class A once where the sweep is easier to create towards tooling direction.
• Create a boundary using limitation points whereever possible for sweep.
• Sweep the above boundaries for industrial standard 3 degree towrads tooling axis.
• Now Create the c surface by using multisection solid where the sweep cant perform.
• Create a boundary by using on the class a surface that is going to pefrom multisection surface.
• Join the surfaces by using multisection surface.
• By using the same method creating the c surface whereever the sweep is not possible.
• After ,join all the c surface.
• Using the same method create c surfaces for all the parts.

* CREATION OF B SIDE ATTACHMENT FEATURES

Creation of Attachment Feature 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

DOG HOUSE

• Extract the surface that we going to create a dog house
• Insert a axis system. use positioned and draw a dog house sketch
• Sweep the sketch to 1.5 degree on the direction of main tooling axis
  • Add thickness to the above sketch of 2.5mm by using thicken surface

• Dog house rule

  B=4mm

  t=2.5mm

  C=0.4 * t=1mm

  • Extract the sweep and offset to b=4mm and c=1mm on all directions like the below
  • Trim the portion to get the required sketch
  • Draft to 0.5 degree along second tooling axis
  • Add fillet to all faces
  • Assemble the doghouse to lower substrate solid
  • Translate the doghouse to wherever we need
  • To place pushpin on the doghouse create a ribs to doghouse
  • Trim the ribs with doghouse

• PUSHPIN

  • Draw a sketch of pushpin by using positioned sketch command
  • Ensure that the sketch is iso constrained
  • Shaft the sketch to 360 degree by using shaft command
  • Add minimum fillets to pushpin
  • Create a sketch to groove the pushpin for 30 degree
  • Use ciruclar pattern command for groove

HEAT STAKES

Heatstakes is known as thermoplastic staking is the process of joining two dissimilar metals together

• Extract the surface that we going to create heat stake
• Use positiioned sketch and draw a heat stakes sketch
• Use pad commands for the sketch to till we required
• Draft the stakes minimum of 0.5 degree
• Add fillet 0.5mm all faces
• Assemble the heat stake to lower subtrate solid
• Maintain a 50mm minimum between two heat stakes
• Translate the heatstakes to wherever we need
• Trim the all heat stakes with lowersubstrate solid

LOCATOR

• Extract the surface that we going to create locator
• Use positiioned sketch and draw a locator sketch
• Use pad commands for the sketch to till we required
• Draft the locator for minimum of 0.5 degree
• Add fillet 0.5mm o all faces
• Assemble the locator to lower subtrate solid
• Maintain a 50mm minimum between two locator
• Translate the locator to wherever we need
• Trim the all heat stakes with lowersubstrate solid
• Maintian a height more than heat stake

FLANGE

Create a flange for attachment of heatstakes and locators at lower substrate

DRAFT ANALYSIS REPORT OF UPPER SUBSTRATE

DRAFT ANALYSIS REPORT OF BOTTLE HOLDER

DRAFT ANALYSIS REPORT OF MAP POCKET

DRAFT ANALYSIS REPORT OF ARM REST

TREE STRUCTURE

WEIGHT OF THE COMPONENT

• Apply material plastic to the product
• Use measure command to caluacute the weight of product

CALCUALTION

Lower substrate=1.217kg

Bottle holder=0.343kg

Arm rest =0.189kg

Upper substrate=0.225kg

The total weight of the product is =1.973kg

* Conclusion:

Creation of the car interior door trim is designed using the given class A surface as the input and Class B and C surface created with the help of Class A surface. By using the given master section attachment features I.e. Heat stakes, Flanges, Dog House and Push Clips are created using the design rules. The draft analysis has been performed to analysis the draft of the component to manufacture easily applying draft to the surface by 3 degree and 0.5 degree to the attachment features. With all data and report we can conclude that draft analysis is very important to design any plastic component to mold the plastic easily. The analysis will verify that all surfaces are favorable for being pulled from a cavity. It may also highlight or given insight to defect areas.