Week 12- Final project

Development of a Door Trim panel

AIM: To design a door trim panel's parts using CAD software, with inputs of class A surface and master section, while adhering to design standards followed by OEM and tier 1 companies.

The objectives of the project are:

1. To generate separate tooling axis for the different parts of the door trim panel and carry out draft analysis on the class A surface.
2. To create class B and class C surfaces by using the provided class A surface as a reference.
3. To combine all the surfaces and create a solid model of the door trim panel.
4. To decide on an attachment strategy for the part and incorporate engineering features in reference to the provided master section.
5. To perform draft analysis on the solid part model with all the engineering features in place.
6. To assemble all the components together to obtain the final door trim panel.

Given Data :- 

In the automotive industry, designing complex products requires more than just simple sketches. This is where the Class A Surface comes in. The A-surface or styling surface is carefully examined to ensure that it is free of gaps and other surface imperfections. It serves as the primary input surface for the design process, and any corrections or alterations to the surface must be approved by or made by the styling team.

A perfect Class A Surface is one where the lines only exist on the edges of the component and its cutouts or holes, giving it a clean and polished look. This surface is critical to the overall design of the product and plays a significant role in achieving the desired aesthetic appeal.

The steps followed for the completion of the door trim panel project are:

1. Checking the given Class A surfaces for any necessary modifications.
2. Segregating the given surfaces into separate part bodies such as Lower Substrate, Arm Rest, Map Pocket, and Bottle Holder.
3. Working individually on each part to create a tooling axis for them.
4. Conducting draft analysis on the Class A surfaces.
5. Creating Class B and Class C surfaces using the provided Class A surface as a reference.
6. Generating closed body models from the Class A, B, and C surfaces.
7. Repeating the above procedure to create all the required parts for the door trim panel.
8. Creating attachment features for all parts.
9. Performing draft analysis on the final parts and constraining them for assembly.

 ARM REST:

Class A Surface -

   The first step in designing the door trim panel is to check the provided Class A surface for any necessary improvements. This involves examining the surface closely to identify any gaps or imperfections that need to be addressed to ensure the final product has a smooth and polished finish. The aim is to make sure that the surface meets the required design specifications, and any modifications made should be approved by the styling team before proceeding with the next step of the design process. Checking the Class A surface is a crucial step as it sets the foundation for the entire project and has a significant impact on the overall aesthetic appeal of the final product.    

             

 

1.                                                                                                                                                                                                                                                                                                       Given class A surafce is not as good as needed . we have to informed styling team for improvement.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                 
2. Improvement of Class A Surafce -                                                                                                                                                                                                                                                                                                                                                                                                                                                                                         

    

            

    As shown in above image I have improved given class A surface in surafce workbench by using surafce operation such as extract, extrapolation , trim etc.

 

• Creation of Tooling Axis - For moulding of Arm Rest we need two tooling axis. Some area get cleared with first tooling axis and reamaining with second one.

 

• Draft Analysis of Class A - 

From above draft analysis we noticed that there is lot of space for improvement of class A surafce. We have to request stlyling team for class A modification.

 

• Creation of Class B Surface -

Class B surface is created by offseting class A surafce by 2.5 mm as per the mastersection. After offseting some area not get offseted , there patches formed. This patches are closed by surface creation features such as fill , multisection , blend etc.

• Creation of Class C surface -

The Class C surface serves as the interface between the Class A and Class B surfaces, and it is crucial for achieving a seamless transition between the two. To create the Class C surface, a sweep operation is typically used. The first step involves extracting the boundary of the Class A surface, which serves as a guide for the creation of the Class C surface. Next, a draft direction is applied at an angle of 3 degrees, and the Class A boundary is swept to generate the Class C surface. This process ensures that the Class C surface smoothly connects the Class A and Class B surfaces, resulting in a seamless and aesthetically pleasing final product.

 

• Creation of Closed Body of Arm Rest - By trimming join of Class A ,C with Class B surface we get close body.

 

• Solid Body of Arm Rest -

 

• Creation of Flanges on Arm Rest -

From mastersection we get the idea of flanges . I have created flanges on Arm Rest by considering counterpart (Lower Substrate) position.

• Draft Analysis on Soild Body of Arm Rest -

Draft is a critical aspect of designing components that are intended to be produced using molds. It refers to the angle added to the walls of a component to ensure it can be easily ejected from the mold without causing any damage to the product. The draft angle is typically added in the direction of the mold's movement or core cavity opening, which helps to facilitate the release of the component from the mold. Without sufficient draft, the component may stick to the mold, leading to damage or unwanted friction that can negatively impact the final product. Therefore, it is crucial to incorporate the appropriate draft angle in the design of the component to ensure its successful production. Typically, a minimum of 1/2 to 1 degree draft is required, but 3 degrees is commonly used as a standard in the industry.

As mentioned above we have two tooling axis for Arm rest.

Following images give the idea about is it manufacturable or not.

 

                                                                               MAP POCKET

 

 Class A Surface -

The initial step in designing the door trim panel involves examining the provided Class A surface closely to identify any areas that require improvement. This is an essential step as it sets the foundation for the entire project and has a significant impact on the final product's overall aesthetic appeal. During this process, the Class A surface is thoroughly checked for any gaps or imperfections that need to be corrected to ensure a polished finish. Any modifications made to the surface should be done with approval from the styling team or completed by them to ensure the surface meets the required design specifications. Checking the Class A surface is crucial to the success of the project as it directly affects the quality and functionality of the final product.

                           

       

 

 

• Creation of Tooling Axis 

 

 

•  Draft Analysis on Class A -

 

From above draft analysis we noticed that all surafce have minimumm 3 degree draft.

• Creation of Class B 

The creation of the Class B surface is a critical step in the design of the door trim panel. It involves offsetting the Class A surface by 2.5 mm as per the master section provided. However, this process can sometimes result in areas of the surface failing to offset correctly, leaving behind patches or gaps that need to be addressed. To address these issues, the surface creation features such as fill, multisection, blend, and others are utilized. These features are used to close the patches and create a continuous surface that seamlessly connects with the Class A and Class C surfaces. This process requires meticulous attention to detail, as any imperfections or irregularities in the Class B surface can impact the final product's appearance and functionality.

•  Creation of Class C 

The Class C surface serves as the connecting surface between the Class A and Class B surfaces, and it is a crucial element in the design of the door trim panel. To create the Class C surface, a sweep operation is performed using the extracted boundary of the Class A surface as input. The sweep operation is carried out with a draft direction set at an angle of 3 degrees to ensure that the final Class C surface can be easily released or ejected from the mold. The result of the sweep operation is a Class C surface that seamlessly connects the Class A and Class B surfaces, creating a continuous and uniform surface that meets the required design specifications. This process requires precision and attention to detail to ensure that the final product is free from imperfections and meets the necessary quality standards.

 

 

 

• Final Solid Body of Map Pocket 

 

 

• Creation of Flanges :

The master section provides crucial information regarding the position and dimensions of various features of the door trim panel, including the flanges. The flanges serve as attachment points for the Arm Rest component, and their creation is an important aspect of the design process. To create the flanges on the Arm Rest, the position of its counterpart, the Lower Substrate, is considered. By carefully analyzing the master section and following design rules used in the automotive industry, the appropriate dimensions and placement of the flanges are determined. These flanges are created with precision to ensure that they provide a secure attachment point for the Arm Rest while maintaining the required aesthetic and functional standards of the door trim panel.

 

• Draft Analysis on Final Body 

 

From above draft analysis we say that map pocket is manufacturable. All Area have minimum Draft of 3 degree.

 

                                                               BOTTLE  HOLDER           

         

• Class A Surface 

1. Check quality of Class A                                                                                           
2. Improved Class A surface

 

 

•  Creation of Tooling Axis

 

•  Draft Analysis on Class A

 From above draft analysis we notice that some area are not have minimum 3 degree darft. Blue colour area shows negative draft for that we have to informed styling team for improvement in class A .

 

• Creation of Class B 

 For creating Class B surface we have to offset it by 2.5 mm as shown in above image.

 

• Creation of Class C

For creating class C surface we have to use sweep feature of surface creation.

 

•  Solid Body of Bottle holder -

 

• Creation of Flanges

 

 

• Draft Analysis on Solid Body of Bottle Holder

 

From above draft analysis we noticed that bottle holder part is not as per requirement. It is not manufacturable because at some area it have negative draft for that we have to informed styling team.

 

                                                                       LOWER SUBSTRACT

 

       

•  Class A Surafce

 

• Creation of Tooling Axis

 

• Drfat Analysis on Class A 

From above draft analysis we say that given class A is of good quality. All area have minimum 3 degree of draft.

 

• Creation of Class B

 Class B created by offseting class A by 2.5 mm.

 

•  Creation of Class C

 

• Creation of Solid Body

 

• Drfat Analysis on Solid Body

From above draft analysis we noticed that all the area have minimum 3 degree of draft.

 

•  Creration of Heat stake 

HEAT STAKES - When designing heat stakes for thermoplastics assembly, it is crucial to ensure that the height of the heat stakes is lower than the height of the locators. This is an important consideration because if the heat stakes are taller than the locators, it can result in improper assembly and a weak joint between the two parts. Therefore, the height of the heat stakes should be carefully determined to ensure proper assembly and a strong joint between the parts.

 

Drfat Analysis on Heat Stake -

• Creation of Locators

LOCATORS - In order to ensure that two components are properly locked together during assembly and to minimize any unnecessary movement between them, locators are used. These locators serve a similar purpose to guide pins found in moulds. The two types of locators commonly used are the two-way locator and the four-way locator. In our model, we have incorporated three four-way locators that satisfy the rib design requirements. By utilizing these locators, we can ensure that the components are securely and accurately assembled, resulting in a high-quality final product.

 

Draft Analysis on Locators -

All the faces of locators have minimum draft 0.5 degree.

 

•  Creation of Dog House 

DOG HOUSE -

• The two main purposes of a dog house are to avoid sink marks and to house various other engineering features like screw boss, locators, push clips etc.
• In this case, the dog house is designed to house the push clips and the 4 way locator. The dog house designed for the push clip features a slot on the top face to accommodate the push clip
• The dog house should follow certain design rules which are stated below

• Doghouse wall thickness at the intersection of the part wall (C) should be 40% or less than the main wall stock (T).
• The height of ( B ) should be between 3.0 – 6.0 mm
• Outer surface of dog house must have a draft angle of 3 degrees
• Inner surface of dog house must have a draft angle of 0.5 degrees

 

 

 

 Draft Analysis on Dog House -

 From above drfat analysis we noticed that outer surfaces of dog house have minimum draft of 1.5 degree and inner surfaces with minimum draft of 0.5 degree.

 

• Lower Substrate with all engineering features-
  
  

 From above image we can see the position of all heat stake , locators and dog house. This all feature created on lower substrate by considering position of its counter parts.

Final Assembly -

For final assembly of door trim panel we have to constarin all parts together. 

Following image shows the Created and assembly of push pin with dog house.

 

In the same way we have to constrain all the parts together.

Following tree structure shows the how all part are constrained and the Final Assembly.

FINAL ASSEMBLY: