Week 12- Final project

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.

Given Data :-

As we know in automotive industry there are complex products that we have to design but this is not possible with simple sketches for that we need Class A Surface.

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.

Steps Follwed for Completion of Project :-

The door trim panel is created by follwing steps -

1. To check given Class A surafces for any modification.
2. To segregate given surafces into separate part body namely Lower Substrate , Arm Rest , Map Pocket , Bottle Holder.
3. To work individually on each part.
4. To create tooling axis for part.
5. Draft analysis on class A surafce.
6. Creation of class B and Class C surafce.
7. Craete closed body from Class A , B and Class C surface.
8. Follwed same procedure to craete all parts .
9. Then create attachement features for all parts.
10. Then do Draft analysis on final parts and then constrain them for assembly.

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 Creation.

Class-B Surface Creation.

Class-C Surface Creation.

Final Surface.

The Class-A, Class-B and Class-C surfaces are joined together to form a closed surface.

Draft Analysis.

Class-A Surface.

Closed Body.

2.LOWER SUBSTRATE.

Given Class-A Surface.

Tooling Axis Creation.

Class-B Surface Creation.

Class-C Surface Creation.

Final surface.

The Class-A, Class-B and Class-C surfaces are joined together to form a closed surface.

• Creation of Dog House.

General Guidlines for Dog House:

• "C" is where the doghouse contacts the backside of the surface.

• 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.

• Minimum Doghouse Width (X) for doghouses is 12 mm.
• Minimum Draft (D) for doghouse is 1.5 degree* to die draw.

• Creation of Heat Stakes.

Thermal staking is an assembly method that uses the controlled melting and reforming of a plastic stud or boss to capture or lock another plastic or metal component of an assembly in place.

Guidelines for creating Heat stakes:

• Minimum 15 mmm gap between heat stakes.
• Maximun clearence with The counter clearence should be 0.5 mm.
• Maximum fillet radius be 0.25 mm..
• Draft : 0.5* per sides.

• Draft Analysis.

Class-A Surface

Closed Body.

3.UPPER MAP POCKET

• Class-A Surface.

• Tooling Axis Creation.

Class-B Surface Creation.

Class-C Surface Creation.

• Final surface.

The Class-A, Class-B and Class-C surfaces are joined together to form a closed surface.

• Creation of Flanges.

• Draft Analysis.

Class-A Surface.

4.LOWER MAP HOLDER.

Class-A Surface.

• Tooling Axis Creation.

Class-B Surface Creation.

• Class-C Surface Creation.

• Final surface.

The Class-A, Class-B and Class-C surfaces are joined together to form a closed surface.

• Flange Creation.

• Final Plastic Component.

Thickness : 2.5 mm.

• Draft Analysis.

Class-A Surface.

Closed Body.

5.PUSH PIN.

Push pin which heilp us locating and arresting component of an assembly and it provide alignment in mating parts and also act as various guide of mechanism. They are bascially attached to the dog house.

Final Door Trim Product Different View.

Conclusion

Door Trim was made with OEM guidelines using Part Workbench and Generative Shape Design Workbench using CATIA V5.