Week 12- Final project
Design And Development Of Door Trim Panel
Aim -
- Create the Car Door Trim Panel with all the parts from the given Class A Surfaces and Master Sections.
- Create the Tooling Direction, Class B & C Surfaces and solid bodies of all parts.
- Create and Assemble the engineering features like Dog-Houses, Heat Stakes, Flanges, Locators and Push-pins.
- Do a Draft Analysis on all parts.
Given Inputs -
- Class A Surfaces of the Door Trim Panel parts, i.e; Armrest, Map Pocket, Bottle Holder and Lower Substrate.
- Master Section for the engineering and attachment features.
- Push-pin for assembly.
Introduction -
- Door Panels serve as an interface between the interior of the car and the inner workings of the door, it covers internal parts like the window regulator, the power window motor, speakers, airbags,the wiring, etc but allows the passengers access to the variety of features included in it.
- They are expected to meet a variety of design specifications regarding safety, aesthetics, and functionality.And carry over the car’s interior theme and design.
Design Of Door Trim Components -
- Separate the components into different parts in an Assembly, and design each part separately before final assembly.
- Analyze each Class A surfaces and rectify/ report the errors if found.
- Create Tooling Axis for each parts, also create a Side-core Tooling Axis if necessary. Make sure that all axes refer to a the same axial direction.
- Offset the Class A surface to form the Class B Surface, after referring to the Master Section to find the thickness.
- Design the Class C Surface with the draft angle in reference.
- Join the Class A and Class C Surfaces, Trim the surface thus formed with the Class B Surface to for a Hollow Surface of the component.
- Make the Hollow Surface a solid by using the CloseSurface command in Part workbench.
- Conduct a Draft Analysis for each component’s Class A surface and the Solid part.
Images of the components -
- Armrest
Class A Surface & Tooling Direction
Class A Surface Defect
Improved Class A Surface
Class B Surface
Class C Surface
Hollow Surface
Solid Component
- Lower Substrate
Class A Surface & Tooling Direction
Class B Surface
Class C Surface
Hollow Surface
Solid Component
- Map Pocket
Class A Surface & Tooling Direction
Class B Surface
Class C Surface
Hollow Surface
Solid Component
- Bottle Holder
Class A Surface & Tooling Direction
Class B Surface
Class C Surface
Hollow Surface
Solid Component
Design Of Engineering Features -
All Sketches used in the designs of each feature is iso-constrained.
- Heat Stakes
- Dog-Houses
- Push-pins
- Flanges
- Locators
Draft Analysis -
All the axes in the images are copies of the Main Primary Tooling Axis and The Main Side-Core Tooling Axis.
- Armrest
Improved Class A Surface
Main Tooling Axis
Side Core Tooling Axis
Solid Component
Main Tooling Axis
Side Core Tooling Axis
- Lower Substrate
Class A Surface
Solid Component
- Map Pocket
Class A Surface
Solid Component
- Bottle Holder
Class A Surface
Solid Component
- Heat Stakes
- Dog-Houses
Main Tooling Axis
Side Core Tooling Axis
- Locators
- Flanges
Main Tooling Axis
Side Core Tooling Axis
Final Components -
- Armrest
- Lower Substrate
- Map Pocket
- Bottle Holder
- Push Pins
Result and Conclusion -
- The A-Pillar Plastic componentsis designed from the given Class-A surfac
- Engineering features are Designed according to themaster section and the design requirements.
- Push-pins are assembled on required spots. And the assembly is constrained properly.
- A Draft analysisis performed on each of the Class A surfaces, the solid Partbody developed from it and all the Engineering features. It’s found that all of them passes the inspection.