Week 12- Final project
Introduction-
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.
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.Arm rest
2.Lower substrate
3.Map pocket
4.Door arm rest
Given data
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.
ARM REST
LOWER SUBSTRATE
MAP POCKET
BOTTEL HOLDER
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.
ARM REST
LOWER SUBSTRATE
MAP POCKET
BOTTEL HOLDER
Class B surface creation
Class B surface includes derived surfaces created by offset operations from class A surfaces to define the thickness of the material. In this file it is important to link Class B surfaces geometrically to enable an adaptation to class A surfaces.
After creation the tooling axis B surface is to be created which is nothing but the surface parallel to the A surface B surface contains all the fillets and the edges which the A surface contains.
ARM REST
LOWER SUBSTRATE
MAP POCKET
BOTTEL HOLDER
Class C surface creation
Class C surface is swept along the boundary of the Class A at an angle perpendicular to the Class A surface with respect to the tooling axis direction with a draft angle of 3 degree.
ARM REST
LOWER SUBSTRATE
MAP POCKET
BOTTEL HOLDER
Joining Class, A, B and C surfaces to get a Closed surface.
After finishing all the 3 surfaces join the Class A and Class C surface together using join command. Now the joined surfaces are then trimmed with the Class B surface to form a Closed surface.
ARM REST
LOWER SUBSTRATE
MAP POCKET
BOTTEL HOLDER
Now switch to Part design and Add the Thickness to the closed surface in order to get the closed solid body.
ARM REST
LOWER SUBSTRATE
MAP POCKET
BOTTEL HOLDER
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 AND HEATE STEAKE
LOCATER
LOWER SUBSTRATE WITH HEATE STAKE,LOCATOR AND DOG HOUSE
map pocket with flange
Door arm rest with flange
BOTTEL HOLDER WITH FLANGES
DRAFT ANALYSIS
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.
ARM REST
LOWER SUBSTRATE
MAP POCKET
BOTTEL HOLDER
Final assembled Door trim panel
