Week 11 - Final project

 DEVELOPMENT OF A DOOR TRIM PANEL

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) Remastring of the given dog house  

d) Performing draft analysis and ensuring the features and surfaces clear it .

INTRODUCTION:

                                                   

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.

Class A Surafce :

• Class surface are the one which will be visible to the customer
• It's the exterior of the parts
• It has a optimal asthetic shape and high surface quality

                                

Class B Surface :

• Class B is the inner side of the Class a surface which will not be seen by the customer  
• where it will faced in the side of core
• where the ejection will make there contact
• It contains the engineering aspects of a model.

Class C Surface :

• Surface that joins class-A and class-B surfaces is class-C surface.
• Which will determine the thickness.
• Class C is often specified for interior surfaces not readily visible.

Tooling Axis :

• The direction in which the mold called the tooling axisor core and cavity opens is Tooling axis
• Considering the ejection from the cavity of the mold after manufactering the interior trim must have the nominal 3 degree draft angle. Hence the tooling axis is crested by considering this factor
• The white clour line is the tooling axis of this surface 

3) DESIGN METHODOLOGY OF DOOR TRIM PANEL :

• Tooling Axis Creation
• Class B surafce Creation 
• Class C Surafce Creation
• Closed Body Creation 
• Draft Analysis 

4) PROCEDURE OF DOOR TRIM PANEL :

The door panel is divided into four parts for easly to design. There are,

1. Door Arm Rest.
2. Lower substrate.
3. Outer Map Pocket.
4. Inner Map Pocket.

A) Door Arm Rest :

Step 1: Design Check (Pre Check) on received Class A :-

• After receiving the Class-A for the connectivity of the surfaces on it.
• Use boundary operation and disassemble.
• Check for discontinuous Surface.
• The check is over if any discontinuities do not arise.

         

Step 2: Determine the tooling Axis :-

• Identify faces which can potentially create problems while manufacturing.
• Surfaces at angles along a desired Tooling Axis.
• Extract a plain surface and create a point on its center for Axis system creation.

         

Step 3: Draft Analysis on Class-A and Possible Creation of Side Tooling Axis :-

• Change View Mode Customization to Material mode.
• Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
• Change the range to 3°. Apply the settings as shown in below image.

          

• The input Class A also has walls having negative angle to the tooling axis.
• This can be an issue while manufacturing the component as it would be very difficult to draw from the molds.
• So, this design needs to consider Various Side Tooling Options.

         

• Here also we can see that some faces are not clearing draft analysis and it is due to the improper class A surface and we have to imform our styling team to modify the class A surface.

Step 4: Class-B Surface Creation :-

This can be done by offseting the class-A surface and by reparing the patches that are forrmed while offsetting the class-A surface.

• First offset the class-A surface
• We can observe it has created patches at two stages.
• So we have to repair them by using multi section surface command.
• Name the developed repaired surface ass Class-B Surface and make it publish.

          

Step 5: Class-C Surface Creation :-

• Extract Class A boundary and convert to Smooth Curve.
• Sweep the curve to the Class A.
• Sweep value should be greater than the Thickness required for part.
• The obtained sweep is shown in Figure.
• Join the Class A Surface with the Class C surface to create a single surface entity.

         

Step 6: Enclosed Surface Creation :-

• Trim the obtained surface with Class B surface.
• Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
• The final Enclosed Surface Obtained is shown in Figure.

        

Closed Surface :-

       Make the final trim to solid part using close surface.

         

Step 7: Perform Draft Analysis on Final Enclosed Surface:

• Change View Mode Customization to Material mode.
• Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
• Change the range to 3°. Apply the settings as shown if Figure.

 

B) Lower Substrate :-

Step 1: Design Check (Pre Check) on received Class A :-

• After receiving the Class-A for the connectivity of the surfaces on it.
• Use boundary operation and disassemble.
• Check for discontinuous Surface.
• The check is over if any discontinuities do not arise.

           

Step 2: Determine the tooling Axis :-

• Identify faces which can potentially create problems while manufacturing.
• Surfaces at angles along a desired Tooling Axis.
• Extract a plain surface and create a point on its center. 
• Create the intersection by using the plane. 
• Create the bisecting line for tooling axis by taking dummy tooling axis.

           

Step 3: Draft Analysis on Class-A :-

• Change View Mode Customization to Material mode.
• Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
• Change the range to 3°. Apply the settings as shown in below image.

         

Step 4: Class-B Surface Creation :-

• The creation of class-B surface can be done by smiply offsetting the class-A surface to the required distance and required direction.

          

Step 5: Class-C Surface Creation :-

• Extract Class A boundary and convert to Smooth Curve.
• Sweep the curve to the Class A.
• Sweep value should be greater than the Thickness required for part.
• The obtained sweep is shown in Figure.
• Join the Class A Surface with the Class C surface to create a single surface entity.

          

Step 6: Enclosed Surface Creation :-

• Trim the obtained surface with Class B surface.
• Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
• The final Enclosed Surface Obtained is shown in Figure.

          

Closed Surface :-

       Make the final trim to solid part using close surface.

           

Step 7: Perform Draft Analysis on Final Enclosed Surface:

• Change View Mode Customization to Material mode.
• Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
• Change the range to 3°. Apply the settings as shown if Figure.

Views of Lower Substrate :

 

C) Outer Map Pocket :-

Step 1: Design Check (Pre Check) on received Class A :-

• After receiving the Class-A for the connectivity of the surfaces on it.
• Use boundary operation and disassemble.
• Check for discontinuous Surface.
• The check is over if any discontinuities do not arise.

        

Step 2: Determine the tooling Axis :-

• Identify faces which can potentially create problems while manufacturing.
• Surfaces at angles along a desired Tooling Axis.
• Extract a plain surface and create a point on its center for Axis system creation.

         

Step 3: Draft Analysis on Class-A :-

• Change View Mode Customization to Material mode.
• Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
• Change the range to 3°. Apply the settings as shown in below image.

         

Step 4: Class-B Surface Creation :-

• The creation of class-B surface can be done by smiply offsetting the class-A surface to the required distance and required direction.

         

Step 5: Class-C Surface Creation :-

• Extract Class A boundary and convert to Smooth Curve.
• Sweep the curve to the Class A.
• Sweep value should be greater than the Thickness required for part.
• The obtained sweep is shown in Figure.
• Join the Class A Surface with the Class C surface to create a single surface entity.

         

Step 6: Enclosed Surface Creation :-

• Trim the obtained surface with Class B surface.
• Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
• The final Enclosed Surface Obtained is shown in Figure.

         

Closed Surface :-

       Make the final trim to solid part using close surface.

          

Step 7: Perform Draft Analysis on Final Enclosed Surface:

• Change View Mode Customization to Material mode.
• Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
• Change the range to 3°. Apply the settings as shown if Figure.

 

D) Inner Map Panel :

Step 1: Design Check (Pre Check) on received Class A :-

• After receiving the Class-A for the connectivity of the surfaces on it.
• Use boundary operation and disassemble.
• Check for discontinuous Surface.
• The check is over if any discontinuities do not arise.

         

Step 2: Determine the tooling Axis :-

• Identify faces which can potentially create problems while manufacturing.
• Surfaces at angles along a desired Tooling Axis.
• Extract a plain surface and create a point on its center. 
• Create the intersection by using the plane. 
• Create the bisecting line for tooling axis by taking dummy tooling axis.

         

Step 3: Draft Analysis on Class-A :-

• Change View Mode Customization to Material mode.
• Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
• Change the range to 3°. Apply the settings as shown in below image.

         

Step 4: Class-B Surface Creation :-

• The creation of class-B surface can be done by smiply offsetting the class-A surface to the required distance and required direction.

         

Step 5: Class-C Surface Creation :-

• Extract Class A boundary and convert to Smooth Curve.
• Sweep the curve to the Class A.
• Sweep value should be greater than the Thickness required for part.
• The obtained sweep is shown in Figure.
• Join the Class A Surface with the Class C surface to create a single surface entity.

         

Step 6: Enclosed Surface Creation :-

• Trim the obtained surface with Class B surface.
• Make Slight Adjustments by extrapolating small values and trimming to obtain a final Enclosed Surface.
• The final Enclosed Surface Obtained is shown in Figure.

          

Closed Surface :-

       Make the final trim to solid part using close surface.

          

Step 7: Perform Draft Analysis on Final Enclosed Surface:

• Change View Mode Customization to Material mode.
• Go to INSERT---> ANALYSIS---> FEATURE DRAFT ANALYSIS and move the compass to the Main Tooling Axis.
• Change the range to 3°. Apply the settings as shown if Figure.

         

5) VIEWS OF DOOR TRIM PANEL ASSEMBLY :

9) CONCLUSION :

Class-B and Class-C Surfaces are created to the given Class-A surfaces. The design of B-side features is done and they are assembled successfully. A detailed report has been prepared and all the part bodies and assembly has been attached to the challenges successfully.