Week 12- Final project

PLASTIC DESIGN - DOOR TRIM PANEL,

Aim:

To create a CAD model as per OEM standards from the below inputs,

• Class A surface
• Nominal thickness : Master sections
• Attachment strategy

Software Used: Catia V5.

Input Given Data:

Introduction:

As per automotive industrial standards to achieve perfect and asthetic shape of door trim or any plastic components base product design perfection is must. Few important neccessory skils as below,

• As a Interior/Exterior Product designer should be aware about the parting surface, parting line, core and cavity know-how is one of the key skill.
• Our design should be manufacturable
• Our design can be easy for assembly,
• And our design should be serviceability.

The below biews for the reference of the door panel mounting portion.

The following material using for trim mfg under thermoplastic materials.

Design rules followed,

Synopsis of the project

In this project we are planning to make the following targets,

• Create thickened part using master section for reference
• Create the mounting features as per design guidelines in the industry and with master sections
• Apply material details :
• Draft analysis & Tooling analysis
• Creation of parting lines and check tooling feasibility.

We have followed below steps to achieve the above outcomes.

Herewith I have showcase the final view outcome view for reference.

The above image is material mode render view.

There is 4 different class A surface provided as a input and we got heatstake before & after view, Flange & component thickness from the provided master section.

The following component we got worked out,

• ARM REST
• LOWER SUBSTRATE
• MAP POCKET
• BOTTLE HOLDER

Here we started to work from Arm Rest.

ARM REST:

provided class A Picture as below,

I got found error on the below highlighted portion on class A.

So at first I did improvement on Class A of arm rest on the specified portion which shows on above image.

Here below the image of Improved Class A of arm rest which I did with support of surface design operation tools.

From the input of our improved Class A surface, i had started to work in order to focus of closed solid body creation.

To create solid body of arm rest we have to do following process,

1. Tooling axis creation
2. Draft analysis
3. Class B creation
4. Class C Creation
5. Final closed body creation.
6. Closed surface thicken by solid.
7. Draft analysis for solid part
8. Parting line creation & tooling feasbility check
9. Engineering feature creation.
10. Material addition.

1. Tooling axis creation:

I have used two methods to create tooling axis, At first i used bisecting method and then had check the draft analysis got found some where below 3 Dgree angles so, next i tried point and direction method and then i did draft analysis in this method also not much difference found in results so i just keep bisecting method outcome line as tooling axis of the arm rest component.

2. Draft Analysis:

I did draft analysis of the by axis consideration bisecting method tooling axis.

The angle results almost cleared the test under minimum limits of drafting angle.

I got found some where below 3 dgree the below images color highlighted with angle limitation.

3.Class B creation:

To create class B I did used Wireframe, Surface & Surface operation tools.

As much as possible way founded to simplify the process to create Class B Surface.

Below picture is reference view of arm rest class B,

to achive class b offset i refered master section for thickness input.

4. Class C Creation:

To create the class C, I extract the class A boundary curve in 3 to 4 batches then I did sweep with input of tooling axis draft direction and extracted the sweep end portions then to connect the extracted surface I did used trim comment.

The final view gets as class C

Class C+ A

These Created Class C join with class A and then I checked the boundary line and its got error in one portion so I extracted the class C as well aside of class a then trim with class A.

And then I got result is Class C + A.

5.Final closed surface creation (Final Trim):

I trimmed the class C+A with Class B to create final closed surface in order make them solid.

I had evaluate my closed surface of arm rest and it got cleared the test there is no any boundary found and it ready to make part body with thicken the closed surface.

6. Closed surface thicken by solid.

7.Draft analysis for solid part

With help of part design I thicken the closed surface and I just tried for draft analysis and its cleared the draft analysis.

8.Parting line creation & tooling feasbility check

So before going to make engineering features we have to checkout tooling feasibility here tooling is the sense we demonstrate the core & Cavity manufacturing feasibility for that we have to create parting surface.

Parting surface is the surface between our components class C side surface which can help to decisions whether the created component can easy eject able from the and we can check it to make tooling axis normal to view mode and see their class C surface looks angular or not.

If the class C is in angular then our component ready to move for next process.

Parting line creation & tooling feasbility check

Parting line creation:

Parting line is the intersection line between the class C+A & Class B.

9. Engineering feature creation:

Now engineering features need to make for assemble the component with door trim panel sub assy.

According to provided master section inputs flange shape dimensions.

With input of this master section we decide to make flange on arm rest at various locations according the general assembly principle of 3-2-1 assembly.

We should arrest the component on 12 face of direction moving possibility with providing 3 axis locking process.

10.Material addition:

I provide plastic material as per normal material providing features.

The above view is complete solid rendering view of arm rest along with engineering features.

LOWER SUBSTRATE

The below image is provided class A.

From the input of our improved Class A surface, i had started to work in order to focus of closed solid body creation.

To create solid body of arm rest we have to do following process,

1. Tooling axis creation
2. Draft analysis
3. Class B creation
4. Class C Creation
5. Final closed Surface creation.
6. Closed surface thicken by solid.
7. Draft analysis for solid part
8. Parting line creation & tooling feasbility check
9. Engineering feature creation.
10. Material addition.

The above procedure same for all following door trim panel and few changes will be there as per class A inputs and master section inputs.

1.Tooling axis creation:

2. Draft analysis:

Provided class A got cleared results as per draft analysis so we can take this to proceed for further process.

3. Class B creation:

4. Class C Creation:

5.Final closed surface creation:

Class C+A,

Final Trim,

6. Closed surface thicken by solid:

7. Draft analysis for solid part:

8.Parting line creation & tooling feasbility check:

9.Engineering feature creation:

Dog house:

Draft analysis for dog house:

The following design rules has been followed to make dog house feature.

Heat stakes:

I get inputs from master section for dimensions of heat stakes,

Draft Analysis for heat stake:

10.Material addition:

The view shows with material addition of plastic.

The above view is complete solid rendering view of arm rest along with engineering features.

MAP POCKET

The below image is provided Class A surface,

I had change the color of class A for easy identifications while process and assemble.

1.Tooling axis creation:

I have used point & Direction method to create Tooling Axis.

2. Draft analysis:

Provided class A got cleared results as per draft analysis so we can take this to proceed for further process.

3. Class B creation:

4. Class C Creation:

5.Final closed surface creation:

Class C+A,

Final Trim,

6. Closed surface thicken by solid:

7. Draft analysis for solid part:

8.Parting line creation & tooling feasbility check:

9.Engineering feature creation:

Draft Analysis for Final body with flanges:

10.Material addition:

The view shows with material addition of plastic.

The above view is complete solid rendering view of arm rest along with engineering features.

BOTTLE HOLDER

The below image is provided Class A surface,

1.Tooling axis creation:

Here, I used point & Direction method to create Tooling Axis.

2. Draft analysis:

Provided class A is not cleared the draft analysis method because we got found 0 Dgree angle in some portion of class A which create issue to make tool core & Cavity.

Below black color elipse shape highlighted portions are got found the 0 Dgree refer below shown in the images,

I have informed to class A given sources but in industries we have to inform the issue to class A Designer or concerned person in charge is very necessary.

And as a plastic designer we dont have authorised modify the class A. But here in order to completeion of task we have to took it further process.

3. Class B creation:

4. Class C Creation:

5.Final closed surface creation:

Class C+A,

Final Trim,

6. Closed surface thicken by solid:

7. Draft analysis for solid part:

In the closed solid body draft analysis report shown the class A issue carry forwarding to the same of further process.

8.Parting line creation & tooling feasbility check:

Accourding to checking of the tooling feasibility, here some portion have no angles and it cant fullfill also least needs so this component not feasible for core & Cavity tool mfg.

9.Engineering feature creation:

10.Material addition:

The view shows with material addition of plastic.

The above view is complete solid rendering view of arm rest along with engineering features.

At final I got assemble all the parts with getherly the push clips. Final door panel view as below,

Material Mode View

Door panel side(Class B side view)