Week 12- Final project
FINAL PROJECT
DOOR TRIM DEVELOPMENT
INPUTS:
- CLASS A surfaces of the DOOR ARM REST, MAP POCKET, BOTTLE HOLDER and LOWER SUBSTRATE.
- Master section for the attachment features.
- Push clips for the assembly.
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 vigrous 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.
- Final submission.
1)CLASS A SURFACE :
- Class-A (or 'Strak') is a term used in specifically in automotive design. It describes the final production surface data for the aesthetic parts of the car.
- The term 'Class A' is often misunderstood, but it's generally seen as the 'Holy Grail' of surface modelling. This is because as it achieves the highest surface quality levels, and it demands a high level of automotive design knowledge as well as surface modelling skills.
- Class A represents the 'craftwork' end of the design process. Creating the main surface shapes to describe the vehicle is the primary design activity. But the painstaking, detailed craftsmanship of perfecting those surfaces, designing flanges and panel gaps is what guarantees that a beautiful design turns into a beautiful manufactured product.
- Here we have four class A surfaces as inputs:
a)ARM REST:
b)LOWER SUBSTRATE.
c)MAP POCKET LOWER ALL
D)POCKET UPPER
2)TOOLING AXIS CREATION :
- Tooling axis plays important role in plastic product manufacturing and designing, this axis decides the direction in which mould is going to work while production of the component.
- The main focus while deciding the tooling axis is clearing the component in the moulding in the same axis with the minimum use of the side core for producing the component, the side core usually adds up to the cost of the component.
- For the particular component X,Y and Z can be the possible direction for the tooling axis.
- You must specify the axis system by creating the point on the surface.
- With the help of the intersect in the YZ plane create the tooling axis in YZ plane .
- With the help of the intersect in the ZX plane create the tooling axis in ZX plane.
- The last step is to bisect the two tooling axis to obtain the main tooling axis of the class A surface.
a)ARM REST:
b)LOWER SUBSTRATE.
MAP POCKET LOWER
POCKET UPPER
3)OVERALL CLASS A SURFACES:
4)CREATING THE CLASS B SURFACE:
- Class B surface is the surface which is created with the help of class A surface as the reference.
- The the class B surface is the surface where all the necessary attachments and supports of the component is made .
- The main parts without the edge fillets are extracted and untrimmed and then they are extrapolated for better view.
- The extrapolated parts are then made offset with reference to the class A with the thickness of the component, here thickness of the component for base bracket is 2.5 mm.
- The offset surfaces are then trimmed to attain the class B surface.
- You can even directly offset the class A for obtaining the class B surface.
- The final class B surface must have the edge fillets similar to the class A and fillets must be given properly with a thought of maintaining same thickness throughout avoiding the flow line defects.
a)ARM REST.
b)LOWER SUBSTRATE.
POCKET UPPER
MAP POCKET LOWER
5)CREATION OF CLASS C SURFACE AND TRIM :
- The class C surface is the surface which is created to provide thickness to the class A surface with the help of class B surface.
- The class C surface is the middle portion of the class A and class B surfaces.
- The class C is created with the help of the sweep command in surface workbench.
- The class A surface's boundary is taken as profile (guide curve) and then tooling axis created is taken as direction of the sweep in subtype draft direction
- The draft angle for the sweep is 3 degrees.
- The holes are created using the same axis and draft angle.
- The attained sweep is joined with class A surface to obtain the class C surface.
- The final trim is obtained by trimming the class B with the class C surface.
- The final check to ensure the proper clossness of surface with the boundary command .
a)ARM REST.
b)LOWER SUBSTRATE.
c)MAP POCKET.
POCKET UPPER
7)CREATING THE ATTACHMENT FEATURES
#HEAT STAKES
- Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic.
- The process is to deform the plastic material using heat and force at a set process time.
- The bond is made by partially de-forming the plastic part in order to fix the other.
- Heat Staking makes it easy to bond metal to plastic and is commonly used in high volume/low cost applications such as automotive, IT and consumer appliances.
- Similar and dissimilar materials may be joined: metal to metal, plastic to plastic, metal to plastic
- Accurate control operating within a small process window
- Local heating resulting in no damage to surrounding materials
- Processing of glass-filled materials
- No mechanical vibration
- Many heat-stake shapes possible through custom designed tools.
#RIBS
- The ribs provide economical stiffness and strength to the part without increasing the overall thickness of the part.
- The ribs are used as locating and arresting in the assembly as locators.
- Proper allignment in mating parts, slot and rib pair is long lasting other than screw pair which loosen up with time.
- Acting as stops or guide for mating the tilted headlamps.
- Rib designs includes.
- thickness, quantity, height , manufacturibility and location.
HERE WE HAVE USED THE LOWER SUBSTRATE FOR THE APPLICATION OF THE HEAT STAKES AND RIBS.
#DOG HOUSE
- Dog house is the attachment feature which helps you to assemble things at certain heights and also resolve the plastic defects.
- There are plenty dog house design which can be used for assembly purpose but we will be using the one provided to ous by the resources.
- The master section or the enginnering drawing must be followed for creating the dog house.
#FLANGES ON THE COMPONENT
- These flanges will be build on the components for the fittment purpose with lower substrate.
- The hole at center will be guided along the heat stakes.
- Later top portion of the heat stake will be melted over it.
- The flange should rest on the supporting ribs on side .
8)DRAFT ANALYSIS OF THE COMPONENTS:
- The draft analysis is done to ensure that the draft in permeasible with the design consideration.
- The draft analysis is done by changing the visualization mode to customize and select shading as material.
- The draft based feature enables us to visualize and examine the draft.
- The draft window is has two tables one is for examining the draft and other one is the colour code.
- The draft value is set in the colour code window with each colour having their own significance.
- The red colour indicates the positive draft less than minimum draft where as the green colour indicates the minimum draft.
- The blue colour indicates the negative draft.
- For visualizing the draft the compass is aligned with the tool axis direction and the cursor is then made clicked upon the surface for viewing the draft.
- The quick view in display window enables to examine the draft value throughout the surface.
- Here both class A and closed body are given the minimum draft as 3 degrees.
- The attachment feature are given draft of 0.5 degrees.