Week 12- Final project

Final project

AIM: Development of a Door Trim panel

CONSIDERATIONS:

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

1. a) Class A surface
2. b) Nominal thickness : Refer master sections
3. c) Attachment strategy :

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.

PROCEDURE:

Indroduction

Door Trim Panel

Door panels serve as an interface between the interior of the car and the inner workings of the door, and between vehicle occupants and the door. They are expected to meet a variety of design specifications regarding safety, aesthetics, and functionality. In addition, they are expected to continue the material theme of the dashboard and pillars while concealing intricate electrical and mechanical components for operating locks, windows, and other features. The door panel has evolved from a simple two-part system of latch and simple winding mechanism to a more sophisticated enclosure. Doors currently have an inner full-width panel consisting of electronic windows, central locking system, and speakers. These panels typically consist of a foamed core covered with either textiles or plastics. Plastics is the core and soul of the door trim interior, one must have knowlege about the plastic being used and its cost associated with the molding and manufacturing.

Class-A surface:

The Class-A surface is the outermost surface of the plastic component which is also looks fine surface and it is the aesthetic surface that the designer creates as an input part for the design work.

Class-B surface:

The Class-B finish is a quality finish with only minimal imperfections. A Class-B finish is the most common finish for exterior surfaces. It is normally specified on surfaces such as external covers, panels, and parts that are fairly prominent.

Class-C surface:

The Class-C finish allows more imperfections than Class-A or Class-B. Class-C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled, or surfaces which the Customer feels do not need to meet a high cosmetic finish.

Tooling Axis:

In Molding, machine arrangement is given to open the mold along a direction which is known as Tooling Direction. In other words. The mold is built from two separate halves (Core and Cavity) and tooling direction basically defines the direction of mold or core pulls apart.

Draft Analysis:

The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values. Most parts or applications require minimum of 1/2 to 1 degree, however 3 degrees is widely accepted as the norm.

Design Methodology:

Components of Door Trim panel:

1. Arm Rest
2. Lower Substrate
3. Upper Map Pocket
4. Lower Map Holder

1.ARM REST

CLASS-A SURFACE

TOOLING AXIS

B SURFACE

C SURFACE

A+B+C

1. Lower Substrate

CLASS-A SURFACE

CLASS-B SURFACE

CLASS-C SURFACE

CLASS A+B+B

SOLICD BODY:

DRAFT ANYLISIS:

3.Upper Map Pocket

• Class-A Surface

TOOLING AXIS:

B SURFACE

C SURFACE

A+B+C

SOLID BODY:

DRAFT ANYLISIS

4.LOWER MAP HOLDER

Class-A Surface.

TOOLING AXIS

B SURFACE

C SURFACE

A+B+C

SOLID BODY

ASSEMBLY

CONCLUSION:

1. Development of a Door Trim panel was done by given Class A surface
2. Attachment strategy : attachment strategy for the door panel complete work.
3. Used Push pin with Dog house for Lower substrate – Door panel attachment
4. Used heat stakes for part to part attachment.
5. all the parts assembly in product file.