Week 12- Final project

                                                                Development of a Door Trim panel

AIM :- To create a CAD model for door trim panel's parts by considering the given inputs of class A surface along with master section by following the design rules followed in OEM and tier1 companies.

OBJECTIVES:

• Analysing the class A  and performing necessary modification to obtain the modified class A.
• Creating the tooling axis for all the components .
• Performing draft analysis of class A surface.
• Creating the class B surface with the help of surface workbench.
• Creating the class C surface with necessary draft.
• Trimmimg the CLASS A,B AND C Surface for obtaining the final trim for all the components.
• Creating the closed body for all the components.
• Creating the attachments on the LOWER SUBSTRATE for assembly like DOG HOUSE, HEAT STAKES, AND RIBS.
• Creating the flanges on the other three components for the assembly purpose.
• Creating the Side core tolling axis.
• Performing the various  draft analysis and make sure all parts are clearing with positive and required draft.
• Assembly of the push pins over the dog house in assembly workbench.

Class A Surface for Door Trim Panel with Master Section:

The A-surface or the styling surface is first checked for any gaps and other issues in its surfaces. This Surface acts as the input surface so any correction to be done should be with approval from the styling team or done by them. A- perfect surface is the one when a boundary is created, the lines are only on the edges of a component and its holes or cutouts as shown below. 

1. ARM REST:

•   Class A Surface -

1. Check Given Class A Surafce for improvement    

 Given class A surafce is not as good as needed . we have to informed styling team for improvement.  

Improvement of Class A Surafce -  

 As shown in above image I have improved given class A surface in surafce workbench by using surafce operation such as extract, extrapolation , trim etc.

TOOLING AXIS CREATION:

Main Tooling Axis and Side Tooling Axis are created in such way to provide drafting.For moulding of Arm Rest we need two tooling axis. Some area get cleared with first tooling axis and remaining with second one.

Draft Analysis Of Class A: using Main tooling axis

By applying drafting analysis at 2.9 Deg, we can see must bodies are been cleared. 

From above draft analysis we noticed that there is lot of space for improvement of class A surafce. We have to request stlyling team for class A modification.

Draft Analysis Of Class A: using side core axis

Creation of Class B Surface -

Class B surface is created by offseting class A surafce by 2.5 mm as per the mastersection. After offseting some area not get offseted , there patches formed. This patches are closed by surface creation features

offsetted class B surface having patches 

patches cloased with surface creation features

Creation of Class C surface -

C surface is the connecting surface of Class A and Class B surface. By using Sweep we created the Class C surface according to tooling axis postion/direction.

Creation of Closed Body of Arm Rest - By trimming join of Class A ,C with Class B surface we get close body.

ARMREST FLANGE CREATIONS

 In order to Join the Armrest body with the other bodies, I created 4 Flanges separately with counter holes, Flanges are different based on the engineering features that will be held. Then these flanges are assembled to the main body (Armrest) by an un-trim feature.

Each Flange was created by extracting the surface from Class C Surface added by Generative Surface. then I applied a close surface feature to create the flange body, Drafted by 0.5 deg, Filleted. Also, it is important to mention that the counter holes were created by iso-constrained, positioned sketches and then padded it and drafted before it was removed from the main flange.

 draft analysis of final body usinf Main tolling axis:

 

using side core axis:

2.  LOWER SUBSTRATE

•   Class A Surface ->:

• Creation of Tooling Axis:

• Drfat Analysis on Class A :

• Creation of Class B:
• Class B created by offseting class A by 2.5 mm.

 Creation of Class C:

• Creation of Solid Body:Class C is created by sweeping Improved Class A Surface and it has been trimed with Class B Surface.

CREATING B-SIDE FEATURES:

FLANGE CREATION:

1. FOLLOW THE MASTER SECTION for the proper dimension of the flange.

• Creration of Heat stake 

HEAT STAKES - 

• Heat stakes are used in thermoplastics to assemble two parts together by locally heating and cooling the plastic material and allowing it to reform itself and act as a joint for the two materials.
• One of the important factor to be considered while designing the heat skates is the height of the heat skates. It should always be less than the height of the locators.

• Creation of Locators

LOCATORS -

• The main purpose of locators is to facilitate proper locking of two components together while assembling and arrest the maximum degrees of freedom possible.
• These locators are similar to guide pins provided in mould.
• The two types of locators used are two way locator and four way locator.

• Creation of Dog House 

DOG HOUSE -

• The two main purposes of a dog house are to avoid sink marks and to house various other engineering features like screw boss, locators, push clips etc.
• In this case, the dog house is designed to house the push clips and the 4 way locator. The dog house designed for the push clip features a slot on the top face to accommodate the push clip
• The dog house should follow certain design rules which are stated below

• Doghouse wall thickness at the intersection of the part wall (C) should be 40% or less than the main wall stock (T).
• The height of ( B ) should be between 3.0 – 6.0 mm
• Outer surface of dog house must have a draft angle of 3 degrees
• Inner surface of dog house must have a draft angle of 0.5 degrees

Lower Substrate with all engineering features-

DRAFT ANALYSIS OF FULL LOWER SUBSTARE:

3.MAP  POCKET 

Class A Surface -:

• Creation of Tooling Axis :

Draft Analysis on Class A :

CLASS-B SURFACE CREATIONS

While offsetting the class-A surfaces to the inward direction, with a 2.5mm thickness of the given plastic parts. I solved the class-B surfaces by finding some gap surfaces, as given below.

Rework the patches and discontinuity of the offset surfaces using the features like extract, multi-extract, sweep, multi-section surfaces, extrapolate, Trim, split, and fillets.

To ensure the continuity of the Class-B surfaces check the boundary command to find out the boundary.

REWORKED CLASS B SURFACE:

•  Creation of Class C 

C surface is the connecting surface of Class A and Class B surface. By using Sweep we created the Class C surface. For that first we have to extract Class A boundary and then with draft direction at angle 3 degree we have sweep the class A extracted boundary. And we get the Class - C surface

DRAW THE FLANGES ON CLOSED BODY AS PER MASTER SECTION:

DRAFT ANALYSIS OF MAP POCKET:

4. BOTTLE hOLDER: 

Class A Surface -:

So the steps are the same for this also first create a tooling axis then offset the Class A surface by 2.5mm so that we can get the Class B surface. After creating the Class B surface we work on the Creation of the Class C surface using the sweep command at an angle of 3 degrees outwards with respect to tooling direction. In some areas, the 90-degree sweep was applied.

•  Creation of Tooling Axis:

•  Draft Analysis on Class A:

Creating CLASS B surface:

Creating CLASS B surface:

•  Solid Body of Bottle holder - kindly do the flanges to part to part attachments

draft ANALYSIS OF BOTTLE HOLDER:

 ASSYMEBLY OF ALL PARTS:

AS PUSH PINS ARE GIVEN , WE HAVE TO PLACE THE PUSHPINS IN THE DOG HOUSE:-ASSYMEBLY WORK BENCH

 FINAL ASSY OF DOOR TRIM PANEL