Week 12- Final project
AUTOMOTIVE PLASTIC DESIGN USING CATIA V5 - PROJECT 2
OBJECTIVE:
Creation of CAD model of the door trim considering following inputs as like in OEM and tier1 companies
- a) Class A surface
- b) Nominal thickness : Refer master sections
- c) Attachment strategy
GIVEN INPUT:
We can devide the entire given input to individual components with their respective part names as:
1. LOWER SUBSTRATE.
2. ARM REST.
3. MAP POCKET.
CREATION OF CAD MODEL OF A COMPONENT:
Each part of the component is created using Generative Shape Design and Part design workbench and assembled together in assembly workbench.
Steps involved in creation of part:
- Creation of tooling axis and draft analysis to check the manufacturability.
- Creation of Class B and Class C surface by using the Class a surface and master section.
- Creation of Closed surface by joining Class A, Class B and Class C surface or trimming them together for the given thickness.
- Creation of thickened solid part
- Creation of engineering features for fixing the parts together and with parent component; in this case door panel.
- Final draft analysis.
- Applying material to the part.
LOWER SUBSTRATE:
Tooling axis with draft analysis result:
The nominal draft angle for tooling is 0.5- 3 degrees.
Draft angle above 3 degrees is represented by green colour and 0.5-3 degrees draft angle is represented by cyan colour. Draft angle below 0.5 degree is represented by red colour.
Improved Class A surface:
The given Class A surface has some missing surfaces for attachment which is available in master section.
Class B surface
Class B surface is created by offsetting the Class A surface to given thickness value available in master section and creating the missing surfaces by using the Improved class A surface and master section.
Class C surface
Final closed surface of the part:
Final closed surface is created by joining Class A, Class B and Class C surface or trimming them together for the given thickness.
Thickened part
Thickened part is created in part workbench from the closed surface created in the generative surface workbench.
Engineering features:
Engineering features like screw boss, locators, heat stakes, dog house can be used for attaching the two or more parts together. In this cad model, master section for heat stakes are given as an attachment strategy and asked to use the push pin/clip for fixing the door trim to the door panel. So heat stakes are created in various required positions for fixing all the components together and doghouse is created for attachment of the push pin/clips.
Heat stake
Dog house:
Final draft analysis:
Final part if checked for tooling along tooling axis and dog house is checked for tooling in along lifter axis.
Along tooling axis:
Along lifter axis:
Material application:
Plastic material is applied to the part.
ARM REST:
Tooling axis with draft analysis result:
Since arm rest part has complex curvature shape, whole part cannot be tooled in one direction. So, side core axis is used. This part can also be created by deviding into two seperate parts.
Along main tooloing axis:
Along side core axis:
Improved Class A surface:
Class a furface with flages for attachment:
Class B surface
Class C surface
Final closed surface of the part:
Thickened part
Engineering features:
Dog house withe heat stake:
Final draft analysis:
Along the tooling axis:
Along side core axis:
Material application:
Plastic material is applied to the part.
MAP POCKET:
Tooling axis with draft analysis result:
Improved Class A surface:
Class B surface
Class C surface
Final closed surface of the part:
Thickened part
Engineering features:
Final draft analysis:
Along main tooling axis:
Along lifter axis:
Material application:
Plastic material is applied to the part.
Given push clip part:
DOOR PANEL AND UPPER SUBSTRATE ATACHMENT DUMMY PART FOR REFERENCE:
FINAL ASSEMBLY:
CONCLUSION:
CAD model of Door trim for the given Class A surface, nominal thickness, attachment stratergy has been created and assembled successfully.