Challenge

Week 12- Final project

NNavaneetha Selvam E25 May 2023

DEVELOPMENT OF DOOR TRIM PANEL:

The aim of the project is to create a thickened part with reference to master section and create attachments features on the B side following the engineering design standards industry guidelines.

In this project we create door trim inner pannel consists of :

Arm rest
Map pocket
Bottle holder
Lower substrate

Creation of Close Surface:

First to ensure the class A surface for patches and discontinuity , Class A gives aesthitic look to the component and visible to the customer. The class A is provided by the styling team to the product designer team.

Draft Analysis:

The draft is given to the part to easy ejection o fthe part from the core and cavity without damaging the walls due to friction.

The draft analysis is performed in the component to check the manufacturing feasibility of the component.

The draft analysis is perform with tooling axis . It is the tooling direction or tool and die direction .

After performing the draft analysis, create the class B surface by offseting the class A surface to the required dimension with refernce to the master section provided.

Then create the class C surface which joins the classA and classB.

These surfaces are created in surface work bench and now we create the solid model thickened in partwork bench using Close surface command. Then perofrom draft analysis on the close component.

ARM REST:

Check the given class A for discontinuity or patches.If there is a discontinuity in the surface then we need to report it to the styling team . Then from the improved classA perform the draft analysis

Draft analysis is perform with min value 3 deg

the draft angle is minimum and the part is difficult to produce and inform to the styling team .

Create the thickened part using close surface :

create the flange to the arm rest for heat stake attachment to the required length following design standards:

draft analysis:

MAP POCKET:

draft analysis on class A surface

Draft analysis on Solid model:

create flanges on the solid part:

BOTTLE HOLDER:

draft analysis on given class A surface:

the red color in the draft analysis shows that the draft on that surface is 0-3 deg

green color region indicates the draft value is more than 3 deg. so in some region the draft angle on class A is minimum than 3 deg

Create solid part using close surface and perform draft analysis :

create flanges to the bottle holder on the required regions according to the attachment plan with hole to features like locators and heat stakes.

draft analysis:

LOWER SUBSTRATE:

Create tooling axis and perform draft analysis on given class A

close surface solid model: draft analysis

Attachment features:

To assemble and attach the components to the door we need to provide attachment features on the B side of the component

Here we create heat stakes and locators for component to component attachment and use push pin with dog house for attachment for door trim to the sheet metal component.

The draft angle should be a minimum of 0.5 deg.

Design of heat stake:

We take refernce from the master section to create the heat stake. There should be a spacing of atleast 50mm between two heat stakes.

By pulse heating a thermoplastic part we can join or bond together two components by heat staking. even disimilar components can also joined using heat staking porcess , unless one of the component should be plastic which sujected to heat and reatin forming a cup or stake.

To provide additional support to the heat stake we create rib to it .

Design of 4-way locators:

Locators are created between heat stakes to provide more stiffnes with in small range gap. A locator should have more height than the heat stake.

Design of dog house:

Doghouses are provided to avoid sink marks by creating the base o fdog house with minimum thickness (40% of the nominal base thickness)

It gives support to lengthen features such as locators , heat stakes, screw boss of more than 100mm height.