Week 11 - Final project

NTRODUCTION:

The door panel is the interface between the interior of the car and inner working of the door. Generally, the door panel is divided in to parts for easy designing like arm rest, map pocket, lower substrate. These require one of the toughest requirements 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.

Method followed in creation of the plastic new product design are

• Tooling axis creation
• Class B surface creation
• Class C surface creation
• Closed body creation
• Draft analysis

Procedure of part creation

Interior door trim consists of four components.

1.Lower substrate

2.Upper substrate

3.Map pocket

4.Door arm rest

Class A surface of all parts of door trim.

In automotive design a Class A surface in any of a set of free form surfaces of high efficiency and quality. Although strictly its nothing more than saying the surfaces have curvature and tangency alignment to ideal aesthetical reflection quality, many people interpret class A surface to have G2 or even G3 curvature continuity to one another. Class A surfacing is done using computer aided digital applications. Class A surface modellers are also called digital sculptors in the industry.

Lower substrate

3.Map pocket

4.Door arm rest

Push pin

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.

Draft analysis of class A surface

The draft analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is based on colour ranges identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values.

Creation of Flanges, Ribs, Dog house and Heat stakes

Dog house

Create the Dog House as per the design rules and give the required draft angle

Dog house wall thickness at a intersection of the part wall (C) should be 40% or less than the main wall stock (T).

Height of (B) should be between 3-6 mm

Ribs

Create the ribs as the design rules and given the required draft angle.

Ribs are created to increase the stiffness and strength of the surface.

Heat Stakes

Heat staking is a pulsed heat process to join two or more parts out of which

One at least is made of plastic.

The process to deform the plastic material using heat and force at a set process time. The bond is made bit partially deforming the plastic part in order to fix the other.

FINIAL PART AFTER ADDING ENGINEERING FEATURES FOR ASSEMBLY

Final assembled Door trim panel