Week 11 - Final project
AIM:
To create the automotive door trim panel from the given class A surface and a thickened part with the required features to locate, mate and assemble the components.
OBJECTIVE:
The door trim panel with the necessary surfaces developed along with the engineering features on the B side surface that constraints with the design standards in the industry. The component when separately created and the features also must follow the draft conditions which inturn ensures the manufacturing or the mould feasibility.
New Product Development - NPD:
The process which involves forming strategy, organizing requirements, generating concepts, creating product & marketing plan, evaluating and subsequent commercialization, thereby bringing a new product to the marketplace.
Product development is a complete cycle which starts from market analysis, product specifications to concept/industrial design, costing, scheduling, testing, manufacturing and ends at logistics, customer feedback, improvements and the final act of getting a product into the market.
This is the procedure followed in the same door trim panel where here a portion is taken out of the entire process and worked on like developing the part component and mating, assembling the components together along with the features necessary to carry out the commands. Also, to ensure and avoid the plastic defects that may arise due to improper or poor design aspect.
DOOR TRIM PANEL:
The door trim panel is one of the major component that make up the interior of an automotive. Generally, they are made out of ABS, or Polycarbonate to withstand higher impact forces.
Class A Surface:
In Automotive design, a Class A Surface in any of a set of freeform surfaces of high efficiency and quality. Although, strictly, its nothing kore than saying the surfaces have curvature and tangency alignment- to ideal aesthetical reflection quality, many people interpret Class A surfaces to have G2 or even G3 curvature continuity to one another. Class A Surfacing is done using computer aided industrial design applications. Class A surface modellers are also called "digital sculptors" in the industry. Industrial Designers Develope their design styling through A-Surface, the physical surface the end user can feel, see, touch etc.
Door Arm Rest
Lower Substrate
Bottle Holder
Map Pocket
Tooling Axis:
Tooling axis is nothing but the direction in which the core and cavity opens and closes. Design engineer works on it to analyse the Class A surface and finds out the best possible tooling direction keeping in mind all the draft angle is with respect to the tooling axis so that the component can be easily ejected from the moulds.
Door Arm Rest
Lower Substrate
Bottle Holder
Map Pocket
Draft Analysis:
The Draft analysis command enables you to detect if the part you drafted willbe easily removed. This type of analysis is based on color ranges identifying zones on the analysed element where the deviation from the draft diection at any point, corresponds to specified values.
Draft anlges are very important in thermoforming product designs. If the product is formed onto a female or negative mould, it shrinks away from the mould side wals. As a result, true female or negative products can be thermoformed with vertical walls having zero draft angles. Parts cannot be ejected from the tool if it is at 90 degree surface. For that reason, a small draft angle is to be provided for each and every surface of the component in order to easy removal of the component from the moulds without any defects. Most of the part require minimum 0.5 degree to 1 degree, however 3 degree is widely accepted in plastic component design. Draft analysis is the technique used to analyse weather our designed product are manufacturable with required conditions are not.
Door Arm Rest
Lower Substrate
Bottle Holder
Map Pocket
Class B Surface Creation;
Class B surface includes derived surfaces created by offset operations from Class A surfaces to define the thickness of the material. In this file it is important to link Class B Surfaces geometrically to enable an adaptation to Class A surfaces Automatically in case of styling change.
After creating the tooling axis, B surface is to be created which is nothing but the surface parallel to the A surface. B surface contains all the fillets and the edges which the A surface contains.
Door Arm Rest
Lower Substrate
Bottle Holder
Map Pocket
Class C Surface Creation:
Class C Surface is swept along the boundary of the Class A at an angle perpendicular to the Class A Surface with respect to the tooling axis direction with a suitable draft angle.
Door Arm Rest
Lower Substrate
Bottle Holder
Map Pocket
Joining Class A,B and C Surfaces to get a Closed Surface:
After finishing all the 3 Surfaces, join the Class A and Class C surface together using Join command. Now, the joined surfaces are then trimmed with the Class B surface to form a Closed Surface. The Attachement feature such as Dog house, Heat stakes, Flanges are created.
Door Arm Rest
Lower Substrate
Bottle Holder
Map Pocket
Draft analysis on Door Trim Solid Body with attachment features:
Door Arm Rest
Lower Substrate
Bottle Holder
Map Pocket
Screenshot view of Door Trim Component
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.