Week 12- Final project

Development of a Door Trim panel

Aim:

Creation of CAD model considering CLass A surface, nominal thickness, and attachment features.

Abstract:

The project report explains steps and procedures followed while developing the Door Trim Panel of a car using CATIA V5. Using the CLASS-A surface and master sections as input, we were able to create a Tooling axis, CLASS-B surface, CLASS-C surface, Flanges and form a solid body after which the attachment features such as Dog House, Push Pins, Heat stakes, etc are created. To check the manufacturability of the parts, a Draft Analysis has also been performed using the main/side tooling axis on various components such as lower substrate, map pockets, armrest, etc.

Objective:

Creation of CAD model considering following inputs as like in OEM and tier1 companies

1. Class A surface
2. Nominal thickness: Refer to master sections
3. Attachment strategy: Flanges, Heat stakes, and Dog house.

Detailed report:

Method followed:

1. Class A modification of given Class A.
2. Creating A Class B and C surface.
3. Create Thickened part using the master section for reference.
4. Create the mounting features as per design guidelines in the industry and with master sections.
5. Performing a draft analysis.

• Lower substrate:

Map pocket:

• Inner map pocket:

• Outer map pocket:

Door armrest:

1. Lower substrate:

To get a Class B,

First of all, we offset the Class A on 2.5mm in the required direction. For intersecting Class B with Class C, we need to extrapolate the offset of Class B.

Next, we need to make a Class C from Class A so we just use a sweeping command with a reference surface of 87 degrees draft angle with the required direction.

2. Map pocket:

Here we divide the Outer map pocket and Inner map pocket by extracting them separately.

• Outer map pocket:

First, we offset the extracted Class A for 2.5mm distance which is the minimal thickness of the component.

Next, we extrapolate by adding edges in the command of Class B to intersect with the C surface.

Then give Multi-Section Surfaces where extrapolate is not working especially in curved sections.

After that, we used to sweep concerning the Class A surface at 87 degrees by visualizing which direction we needed to sweep the surface.

• Inner map pocket: we did the same operations which are followed for the outer map pocket.

3. Door armrest:

In, Door armrest we divided it into parts by extracting it separately and worked on it to neglect the error on the Class B surface.

We have done the same operations on door armrests which apply on map pockets and the lower substrate.

Class A and B surface:

Joining Class A and c surface:

Trimming it with extrapolated Class B

3. Create a solid body using the master section for reference:

First, we go to the part workbench, next create a new body then use a close surface feature and finally we get our final output of a nominal thickness of 2.5mm measured from master sections.

Lower substrate

BOTTLE HOLDER

Outer map pocket

Door armrest

4. Creating the mounting features as per design guidelines in the industry and with master sections:

• Flanges:

First, we extract the curve that lies on the body

Next, we make a point on it and use a point repetition operation with the distance between 60-100 according to the design rule for flanges

Then add the plane and sketch the flange and constraint it.

• Heat stakes:

First of all, we made a point on the surface in the middle of both sides.

Next, I need to make a plane by offset from the plane then make two circles of D10 & D9.4. Bigger circle for making a hole on a flange and another one is for heat stake.

Result & Conclusion:

A Door Trim Panel with engineering features using the master section and styling surface as an input has been successfully created and draft analysis has also been performed for the same.