Challenge

Week 12- Final project

AAkash Harish Shetty23 May 2023

Objective: To design the Lower Door Trim of the door from the given Class-A Surface in Catia -V5.Objective: To design the Lower Door Trim of the door from the given Class-A Surface in Catia -V5.

Project Overview:

Door Trim is the interior component attached to the inferior side of the door. It's a vital component which provides aesthetic look to the interior of the car and also provides features and functions for the passengers. In this project we are going to design the lower portion of the door trim from the given Class-A Surface. Also we would be designing the B-Side Features on the component by following the industry standards and design rules.

Workbench and its Toolbar used:

Generative Shape Design Workbench

Surface Toolbar
Wireframe Toolbar
Operation Toolbar

Part Workbench

Sketch Based Feature Toolbar
Dress up Features Toolbar
Surface Based Feature Toolbar

Theory:

Tooling Axis - Tooling Axis is the direction in which the component will be ejecting after the molding process is completed. The rules of selecting an optimum direction of tooling axis for any particular component is as follows :-

The direction of the tooling axis should be clearing the maximum number of portions of the component once the molding process is completed.
The direction of the tooling axis should be selected such that the number of side cores required should be minimum, as inserting side cores causes a rise in production cost.

Drafting - Draft is the inclination given to any particular plastic component’s cavity walls in order to achieve easy ejection, once the process is completed.

Consider that the draft angle between the plastic component and the core is zero.
When the molten plastic inside the cavity cools, it sticks to the walls of the core.
During such zero draft condition, the ejection of the plastic component causes friction between them which might bring damage to both the core and the component.
This damage further leads to inefficiency in the production & also affects the product’s surface finish.
Hence, a minimum of ½ to 1 deg draft is provided to help in releasing the component.
However 3 deg draft is widely accepted as a norm in the industry.

Prerequisites before creating the tooling axis and performing draft analysis-

Ensure that the Class A surface imported should be a single surface.
This can be checked using the Boundary tool in the Operation Toolbar.
If the surfaces are disassembled, join them using Join command which is also found in the Operation toolbar.

Creating any component from Class A Surface ( Overview ) -

Decide a suitable tooling axis direction and create the Tooling Axis.
Perform Draft analysis for analyzing whether the drafts on the component follow the industry standards.
Create another surface ( B Surface ) offset to the Class-A Surface. The offset distance should be equal to the thickness of the component.
Create a C- Surface ‘Sweeping’ the boundary of Class-A -Surface along the Tooling Axis.
Trim Class- A surface with B-Surface and C Surface to create a closed surface.
Finally create the solid part from this surface to obtain the desired component.

I] Class-A Surfaces:

Firstly we observe the Class-A Surface and understand how the component can be manufactured.

Observing the Master Sections:

Draft Analysis Of Class-A Surface:

Draft Analysis is performed on the component in order to check whether the component can be manufactured or not.
This Draft Analysis tool in Catia allows us to analyze the drafts provided on the surface.
We can check whether they follow industry standards and if not we can modify it accordingly.

Lower Substrate:

Map Pocket:

Bottle Holder:

Arm Rest:

Designing the Solid Component from Class-A:

NOTE: The representation below of the steps mentioned above are for the Lower Substrate only. Similar steps were performed for designing other components

Class-A Surface:

B Surface:

class A+C:

closed Surface:

Arm Rest:

Map Pocket:

Bottle Holder:

Dog House: Many times the screw bosses or push pins need to be given extra length in order to perfectly assemble with other components. We can’t directly increase their height, as all the components are made with proportion to the width and thickness of the component. This can cause sink marks on the component. Hence we provide a dog house wherever necessary and place our engineering feature above it for perfect finish of the component.

Design Rules For Dog House:

Sink Saver Thickness = 0.4 * Thickness of the Dog House
Length of Sink Saver = 3 mm to 6 mm
Upper Width = 12 mm
Outer Draft = 1.5 deg minimum
Draft for lifter Axis = 0.5 deg.