Challenge

Week 12- Final project

REPORT:

AIM:

To develop the assembly of door trim panel by using CATIA V5 design Software.

OBJECTIVES:

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

Find a attachment strategy for the door panel complete work.

Use Push pin with Dog house for Lower substrate – Door panel attachment

Use heat stakes for part to part attachment

OUTPUT REQUIRED:

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

Given Class A surface:

TOOLING AXIS CREATION:

Tooling axis is fixed in all individual component by looking at the view where the component looks complete.
In this surface Y direction view is capable for that so decided to make a tooling axis line according to the Y direction.
So, Extracted flat surface individually in all component and fix a point on surface and created a line of normal to surface.
Now indicates that line as "Tooling Axis" Whereas Arm rest tooling axis is named as "side tooling axis" because it is located in side portion according to arm rest.
Arm rest need another Tooling axis in Z direction.

B SURFACE CREATION:

B surface are build by taking offset from the given A surface.
The offseted surface may come without some sub elements.
That sub element should create by using Extract, Extraplote, Join,Trim command as per the design rules.
After the build of sub element in the offseted part its should be extend through all edges by using extraplote and sweep command as per design rules.
This extended process are done to get trimed with A+C surface.

C SURFACE CREATION:

This surface is created by taking reference as outer bounadary of Class A surface.
Sweep command is used to enlarge the surface fom the boundary.
It should be done according to the design rules where should be in 90* or 3* with draft direction or reference surface according to the surface.
After the sweep process the edges of the sweep are extraplote and trimed.
Then the trimed C surface and A surface are joined and name as "Join A+C".
This process is done individually to all four surfaces.

Parting line:

Parting line is nothing but it is a intersection line between "Join A+C" and "B surface".
This parting should complete without any interval of line.
Then only the Final trim operation takes place.

Final trim:

The joined surface "Join A+C" are trim with B surface.
This process should undertook without any boundary limit then only the next process closed surface should happen.
So after that check it by using boundary command.

DRAFT ANALYSIS:

The draft analysis technique is used to analyze whether our part model created in Catia is manufacturable based on the draft condition applied.
First fix the compass in the tooling axis line by selecting the compass in the draft analysis and check the A surface first.
If there is any mistake it visually evaluates surface draft-angle using false-color analysis (red).when this A surface is cleared then only we have go to next step.
Angle also be checked in given class A surface then class B and class C surface are developed.
After the development of class B and C again the Checking process in draft analysis are held.
Then the mistakes are cleared and get back to draft analysis for checking it should be in green in upper cavity surface and blue in lower mould surface.
This process is done individually to all four surfaces.

NOTE: Some parts may be defective after counselling to the Mentor they said it may be design problem from the given A surface. Kindly consider.

MASTER SECTION:

The Engineering attachment reference are taken from the given master section as follows:

Heat stakes:

The Heat stakes are sketched by taking reference from the given master section and paded according to the master section length.
Then draft and filllet are done as per the design rules.
After the one Heat stakes and Locator are build it is copied and paste the point according to the flanges.

Flanges:

The Flanges are sketched by taking reference from the given master section and paded according to the master section length.
Then draft and filllet are done as per the design rules.
This flanges are not like heat stakes its should be sketch paded again and again according to C surface of the component.
This process is done individually to all four surfaces.

ENGINEERING ATTACHMENTS:

This are the attachments which used to fix the compents while assembling as a part to part attachment.
In this Door assembly Lower Substrate is a primary part because the heat stakes, locator and Dog house are attached here.
The other components should only have Flanges.
This Flanges,Heat stakes, locator and dog house are should be done taking reference from master section and draft analysis taken according to the design rules (0.45 degree).
At the end the push pin are placed and inserted in the Dog house.
This push pin are placed in product assembly by existing component of push pin and coincidence constraints.
Then placed on the top of the Dog house.

Result:

The thickened part using master section for reference are created.
The mounting features as per design guidelines in the industry and with master sections are created.
The material detail Draft Analysis and Tooling axis are applied.
Parting lines are created to check tooling feasibility.
Master section reference are taken to build Engineering attachments.
Heat stakes are used for part to part attachment.
Push pin with Dog house for Lower substrate are used.

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Note: The entire 'Save management' folder are attached.

Ship work like this
in your own course.