Challenge

Week 11 - Final project

HHisham Ahamed Mp11 Mar 2023

WEEK 11 - FINAL PROJECT

Aim:

To design and develop the vehicle interior door trim using given class A surfaces along with Master section.Also to create the B-Side Attachment features as per design rules.

Objectives:

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.

Introduction:

Pic.1 (Door Panel)

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.

Pic.2 (Door Panel with Sheet metal Component & Plastic Component)

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.

Methodology:

Creating the Tooling Axis
Creating Class B surfaces.
Creating Class C Surfaces:
Creating Solid Body
Creation of Attachment Features to the Door Trim
Performing Draft Analysis

1.Creating the 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. The step by step procedure of creating the tooling axis is given below.

Arm Rest :

Creating the tooling axis for Arm Rest by create a point on surfaces respectively with Axis system. Now create the intersection for Z-Y AND Z-X axis respectively based on the point.Then,Creating the bisecting line to the both intersection and create bisect for that lines. Hence we get final tooling axis for the Arm rest.

Pic.3 (Arm Rest Main Tooling Axis)

Creating the Side core Tooling axis for the arm rest by extracting the side walls of the surface. Creating the point on the surface with axis system, here y axis is considered as removal direction, hence line is created to the y axis as shown below.

Pic.4 (Arm Rest Side Core Axis)

Lower Substrate :

Creating the tooling axis for Lower Substrate by create a point on surfaces respectively to the 0 value. It automatically create at mid surface and generate the line to the direction of y axis.

Pic.5 (Main Tooling Axis)

Map Pocket:

Creating the tooling axis for Map Pocket by create a point on surfaces respectively to the 0 value. It automatically create at mid surface and generate the line to the direction of y axis.

Pic.6 (Main Tooling Axis)

Bottle Holder:

Creating the tooling axis for Bottle Holder by create a point on surfaces respectively to the 0 value. It automatically create at mid surface and generate the line to the direction of y axis.

Pic.7 (Main Tooling Axis)

2.Creating Class B surfaces

Creating the Class B Surface by extracting the class A surface, by each surfaces separately, it is offset to certain distance(2.5mm inward or outward respectively), making point on the master section to get the intersection as shown below.

Arm Rest :

Pic.8

Lower Substrate:

Pic.9

Map Pocket:

Pic.10

Bottle Holder:

Pic.11

3.Creating Class C Surface

For Creating Class C Surface we have to extract the boundary of Class A surface and it is make into smooth curves to sweep the curves by using support surface to the 90 degree respectively.Once the all surface joined together it extrapolated to certain distance to trim with A Class surface to C surface. Finally we created Class C surface.

Arm Rest :

Pic.12 (Class C)

Pic.13 (Class A+C)

Lower Substrate:

Pic.14 (Class C)

Pic.15 (Class A+C)

Map Pocket:

Pic.16 (Class C)

Pic.17(Class A+C)

Bottle Holder:

Pic.18 (Class C)

Pic.19 (Class A+C)

4.Creating Solid Body

To make the final component the Class C surface is trimmed with Class B surface, the output will get the component with (2.5mm) thickness of surface and it is converted into solid body using insert body option in part design as shown below.

Arm Rest :

Pic.20 (Closed Surface)

Pic.21 ( Solid Body)

Lower Substrate:

Pic.22 (Closed Surface)

Pic.23 ( Solid Body)

Map Pocket:

Pic.24 (Closed Surface)

Pic.25 ( Solid Body)

Bottle Holder:

Pic.26 (Closed Surface)

Pic.27 ( Solid Body)

5.Creation of Attachment Features to the Door Trim

Dog House:

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.

Pic.28 (Reference Dog House)

Using this reference ,I have made one sketch on Lower Substrate Plane then paded it on a part body.we have to make one Side core axis to it too.Then made another sketch fot the supporting ribs inside the dog house by extruding and then thickening it.After union triming suporting ribs to the house i have given drafting to it .and then i have given the coring to the inside lower part for the the slider to act easily.and For the final touch i have given the fillets.

Pic.29 (Dog House with Sketch & Side Core Axis)

Pic.30

Pic.31

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.

Pic.32

Creating the sketch by extracting the class A surface of Lower Substrate. point and axis system created simultaneously on the surface. Using positioned sketch Draw 2 circles and pad it and give draft of 0.5deg then draw another sketch for Suppoerting ribs then pad it and thicken .After that union trim supporting ribs with Heat stakes. Give draft of 0.5deg to supporting ribs too.

Four Way Locator:

Four way mean you prevent movement at 2 axes (+X, -X, +Y and -Y) on the plane. Generally, you have cylindrical pin on the fixture and circular hole at workpiece part.

Pic.33

Creating the sketch by extracting the class A surface of Lower Substrate. point and axis system created simultaneously on the surface. Using positioned sketch Draw 2 Line Perpendicularly and pad it with thicken and give draft of 0.5deg then give chamfer of 1 mm & 45deg andgive fillets.

Flanges:

Pic.34

Pic.35

Pic.36

B Side Features:

Pic.37

Push Pin:

Pic.38

Pic.39

6.Performing Draft Analysis

The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on colour ranges identifying zones on the analysed component where the deviation from the draft direction at any point, corresponds to specified values. This rule of thumb applies to parts with mold depths of up to 2 inches. At this size, draft as low as 1½ degrees will allow for an easy, non-damaging release from the mold when the expected shrinkage of the thermoplastic material occurs.

It’s also important to remember that draft angles are just one component of an effectively designed injection molded piece. Design for manufacture is one of the easiest ways to improve the quality and efficiency of your injection molding process, and it never hurts to stay up to speed on all injection molding best practices.

Draft Analysis of Class A Surface:

Arm Rest: