Week 12- Final project

REPORT ON DOOR TRIM PANEL

AIM-

TO DESIGN AND DEVELOP DOOR TRIM PANEL USING CATIA V5 FROM A GIVEN CLASS A SURFACE ALONG WITH MASTER SECTION, ALSO CREATE THE ENGINEERING FEATURES AS PER DESIGN RULES.

OBJECTIVES-

• TO CREATE TOOLING AXIS AND PERFORM DRAFT ANALYSIS.
• TO CREATE THICKENED PART FROM GIVEN CLASS A SURFACE USING MASTER SECTION AS A REFRENCE.
• TO CREATE ENGINEERING FEATURES AS PER DESIGN RULES OR MASTER SECTION AS A REFRENCE.

INTRODUCTION-

• THE DOOR TRIM PANEL IS THE INTERIOR PARTS THAT CONTAINS MOST OF THE CONTROLS AND DECORATIVE OR AESTHETIC PARTS.
• THE AESTHETIC PART WILL BE VISIBLE AND FULL OF ART, ARTITECTURE, DESIGN AND CRAFT.
• THE OTHER SIDE OF AESTHETIC PART WILL BE FULL OF MOUNTING OR ENGINEERING FEATURES WHICH HELPS IN ATTACHING THE PLASTIC COMPONENT TO THE SHEET METAL COMPONENT AS SHOWN IN ABOVE FIGURE.
• THE DOOR TRIM PANEL CONSISTS PARTS LIKE ARM REST, LOWER SUBSTRATE, UPPER SUBSTRATE, MAP POCKET AND BOTTLE HOLDER OR LOWER MAP POCKET ETC,.
• THE DOOR TRIM PANEL SHOULD BE DESIGNED IN SUCH A WAY THAT IT SHOULD WITH STAND LOAD AND PROTECT THE OCCUPANT DURING COLLISION.

IN THIS CHALLENGE TO DESIGN AND DEVELOP THE DOOR TRIM PANEL WE ARE GIVEN WITH THESE 4 PARTS WHICH ARE AS FOLLOWS-

• ARM REST.
• MAP POCKET.
• LOWER SUBSTRATE.
• LOWER MAP POCKET/BOTTLE HOLDER.

INPUTS-

• HERE WE WILL BE PROVIDED WITH CLASS A SURFACE AND MASTER SECTIONS AS AN INPUT.
• THE CLASS A SURFACE IS ALSO CALLED AS AESTHETIC PART OF THE COMPONENT WHERE IT IS CREATED USING ALIAS SOFTWARE AND IT SHOULD NOT HAVE ANY MOUNTING FEATURES ATTACHED TO IT.  
• MASTER SECTIONS ARE THE GUIDES FOR DESIGN REQUIREMENTS WHICH HELPS IN IDENTIFYING THE LOCATION OF ENGINEERING FEATURES AND ATTACHMENTS FEATURES LIKE RIBS,DOG HOUSE, SCREW BOSS, LOCATORS, FLANGES AND ALSO PROVIDES THE DIMENSIONS OF THE COMPONENT.
• USING CLASS A SURFACE THE CLASS B,C SURFACES ARE CREATED.

THE CLASS A SURFACES OF THE DOOR TRIM PANEL ARE AS FOLLOWS-

1.ARM REST-

2.MAP POCKET-

3.LOWER MAP POCKET/ BOTTLE HOLDER-

4.LOWER SUBSTRATE-

THE STEPS INVOLVED IN DESIGN AND DEVELOPMENT OF DOOR TRIM PANEL ARE AS FOLLOWS-

STEP 1: TO CHECK THE QUALITY OF CLASS A SURFACE

THE QUALITY OF THE CLASS A SURFACE CAN BE DETERMINED AS FOLLOWS-

• THERE SHOULD NOT BE ANY SMALL GAP BETWEEN TWO SURFACES WHICH ARE CONNECTED.
• SURFACES SHOULD NOT HAVE ANY SHARP EDGES.
• THE SURFACES SHOULD CLEAR THE DRAFT ANALYSIS.

IN CASE OF ARM REST AND BOTTLE HOLDER THE QUALITY OF CLASS A SURFACE IS NOT GOOD, SO THE CLASS A SURFACES HAS BEEN IMPROVED..

1.THE IMPROVED CLASS A SURFACE OF ARM REST ARE AS FOLLOWS-

BEFORE-

AFTER-

2.THE IMPROVED CLASS A SURFACE OF BOTTLE HOLDER ARE AS FOLLOWS-

BEFORE-

AFTER-

STEP 2: TOOLING AXIS CREATION

• THE AXIS ALONG WHICH THE CORE AND CAVITY OPENS DURING OPERATION IS CALLED TOOLING AXIS.
• TOOLING AXIS ARE CREATED IN SUCH A WAY THAT ALL THE SURFACES OF THE COMPONENT SHOULD BE VISIBLE IN THAT DIRECTIONS.
• IN SOME CASES WHERE THE SURFACES ARE NOT VISIBLE THEN BISECTING METHOD IS USED OR SIDE CORE AXIS /LIFTER AXIS CAN BE INTRODUCED WHICH MAY INCREASES THE TOOLING COST.

1.TOOLING AXIS FOR ARM REST-

• THE ARM REST CLASS A SURFACE CONSISTS OF ONE MAIN TOOLING AXIS AND TWO SIDE CORE AXIS.
• DUE TO COMPLEXICITY OF SOME SURFACES WHICH WERE UNABLE TO CLEAR SO THE SIDE CORE AXIS HAS BEEN INTRODUCED.
• HERE THE TOOLING AXIS ARE CREATED ALONG Z AND Y DIRECTIONS WHICH IS AS SHOWN IN ABOVE IMAGES.

2.TOOLING AXIS FOR MAP POCKET-

• MAP POCKET CLASS A SURFACES ARE VISIBLE ALONG Y DIRECTIONS SO THE SINGLE TOOLING AXIS IS CREATED ALONG Y DIRECTIONS AS SHOWN IN ABOVE IMAGES.

3.TOOLING AXIS FOR LOWER MAP POCKET/ BOTTLE HOLDER-

• SOME OF THE LOWER MAP POCKET CLASS A SURFACES ARE NOT VISIBLE ALONG Y DIRECTIONS SO BISECTING METHOD IS USED TO CONSTRUCT THE TOOLING AXIS. 

• USING THE INTERSECT TOOL ALONG X DIRECTION THE BOUNDARY IS OBTAINED. THE LINES ARE DRAWN ON THESE BOUNDARY AND ARE BISECTED TO OBTAIN A LINE AS SHOWN IN ABOVE IMAGES.

• SIMILARLY THE INTERSECT TOOL IS USED ALONG Z DIRECTIONS AND THE LINES ARE DRAWN WHICH IS INCLINED AT 3 DEGREES FROM THE SURFACE AS SHOWN IN ABOVE IMAGES.

• BOTH THE LINES ARE AGAIN BISECTED TO OBTAIN THE TOOLING AXIS AS SHOWN IN ABOVE IMAGES.

4.TOOLING AXIS FOR LOWER SUBSTRATE-

• THE LOWER SUBSTRATE CLASS A SURFACES ARE VISIBLE ALONG Y DIRECTION, SO THE TOOLING AXIS IS CONSTRUCTED ALONG Y DIRECTIONS. 

STEP 3: DRAFT ANALYSIS ON CLASS A SURFACE

• THE DRAFT ANALYSIS IS DONE SO THAT THE SURFACES CLEARS CORE OR CAVITY SIDE, DUE TO WHICH THE COMPONENT CAN BE EASILY MANUFACTURED.
• TO CONDUCT A DRAFT ANALYSIS CHANGE THE SHADDING TO MATERIAL MODE IN CUSTOMIZATION VIEW PARAMETER TOOL, THEN SELECT THE DRAFT ANALYSIS TOOL AND CLICK ON COMPASS.
• PLACE THE COMPASS ON THE TOOLING AXIS CAREFULLY AND LOCK IT.
• SELECT THE SURFACES AND THE DREAFT ANALYSIS IS SHOWN IN THE FORM OF COLOUR CODES.
• WE CAN FLIP THE DIRECTION TO CHECK THE OTHER SIDE SURFACE FOR DRAFT ANALYSIS. 

1.DRAFT ANALYSIS FOR ARM REST-

2.DRAFT ANALYSIS FOR MAP POCKET-

3.DRAFT ANALYSIS FOR LOWER MAP POCKET/BOTTLE HOLDER-

4.DRAFT ANALYSIS FOR LOWER SUBSTRATE-

• BASED ON ALL THE RESULTS FROM DRAFT ANALYSIS WE CAN CONCLUDE THAT THERE IS NO NEGATIVE DRAFT ON THE SURFACE AND CAN BE MANUFACTURED. 

STEP 4: CREATION OF CLASS B SURFACE

• IF THE GEOMETRY IS SIMPLE AND CONSISTS LESS NUMBER OF SURFACES THEN EACH SURFACES ARE SELECTED AND OFFSETED, TRIMMED TOGATHER TO FORM A CLASS B SURFACES.
• IF THE GEOMETRY IS COMPLEX AND CONSISTS MORE NUMBER OF SURFACES THEN WHOLE CLASS A IS OFFSETED. DURING THIS PROCESS SOME OF THE FILLETS WILL BE MISSING AND THES HAS TO BE SOLVED SEPERATELY USING VARIOUS TOOLS LIKE MULTIPLE EXTRACT, EXTRUDE, UNTRIM, TRIM, SPLIT ETC., TO OBTAIN CLASS B SURFACE. 

1.CLASS B SURFACE FOR ARM REST-

AFTER OFFSET-

• SOME OF THE FILLETS ARE MISSING AFTER USING OFFSET TOOL.

FINAL CLASS B SURFACE-

• ON SOLVING THE MISSING FILLETS THE CLASS B SURFACE FOR ARM REST IS FORMED AS SHOWN IN BELOW IMAGES. 

2.CLASS B SURFACE FOR MAP POCKET-

• ON USING OFFSET TOOL THE CLASS B SURFACE FOR MAP POCKET IS DIRECTLY FORMED WITHOUT MISSING OF ANY FILLETS AS SHOWN IN BELOW IMAGES.
• SOME OPERATIONS LIKE EXTRAPOLATE IS DONE SO THAT IT CAN INTERSECT WITH THE CLASS C SURFACES.

3.CLASS B SURFACE FOR LOWER MAP POCKET-

• ON USING OFFSET TOOL THE CLASS B SURFACE FOR LOWER MAP POCKET IS FORMED DIRECTLY AS SHOWN IN BELOW IMAGES.
• SOME OPERATIONS LIKE EXTRAPOLATE IS DONE SO THAT IT CAN INTERSECT WITH THE CLASS C SURFACES.

4.CLASS B SURFACE FOR LOWER SUBSTRATE-

• ON USING OFFSET TOOL THE CLASS B SURFACE FOR LOWER SUBSTRATE IS FORMED DIRECTLY AS SHOWN IN BELOW IMAGES.
• SOME OPERATIONS LIKE EXTRAPOLATE IS DONE SO THAT IT CAN INTERSECT WITH THE CLASS C SURFACES.

STEP 5: CREATION OF CLASS C SURFACE

• TO CREATE AN CLASS C SURFACE WE HAVE TO TAKE CLASS A SURFACE, CREATE A BOUNDARY ALONG THE CLASS A AND SWEEP WITH RESPECT TO SURFACE OR TOOLING AXIS.
• IF THE SURFACE FORMED IS PARALLEL TO THE TOOLING AXIS THEN PROVIDE 3 DEGREE DRAFT ANGLE.
• IF THE SURFACE FORMED IS PERPENDICULAR THEN SWEEP IS CREATED AT 90 DEGREE ANGLE.

1.CLASS C SURFACE FOR ARM REST-

2.CLASS C SURFACE FOR MAP POCKET-

3.CLASS C SURFACE FOR LOWER MAP POCKET-

4.CLASS C SURFACE FOR LOWER SUBSTRATE-

STEP 6: JOINING OF CLASS A AND CLASS C SURFACES

• USING JOIN TOOL THE CLASS A AND CLASS C SURFACES ARE JOINED.

1.ARM REST-

2.MAP POCKET-

3.LOWER MAP POCKET-

4.LOWER SUBSTRATE-

STEP 7: FINAL TRIM

• HERE THE JOINED CLASS A AND CLASS C SURFACES ARE TRIMMED WITH CLASS B SURFACES TO OBTAIN THE CLOSED SURFACES (HOLLOW COMPONENT).
• THERE SHOULD NOT BE ANY OPEN BOUNADRY ON THE SURFACES, IT CAN BE CHECKED BY USING THE BOUNDARY TOOL.

1.FINAL TRIM FOR ARM REST-

2.FINAL TRIM FOR MAP POCKET-

3.FINAL TRIM FOR LOWER MAP POCKET-

4.FINAL TRIM FOR LOWER SUBSTRATE-

STEP 8: CONVERTING CLOSED SURFACE INTO SOLID COMPONENT-

• THE CLOSED SURFACE IS CONVERTED INTO SOLID COMPONENT USING THE CLOSE SURFACE TOOL IN PART WORKBENCH.

1.ARM REST-

2.MAP POCKET-

3.LOWER MAP POCKET-

4.LOWER SUBSTRATE-

STEP 9: ATTACHMENT OF ENGINEERING FEATURES

• ENGINEERING OR MOUNTING FEATURES ARE USED TO ATTACH PLASTIC COMPONENT WITH EACH OTHER OR WITH SHEET METAL SO AS TO ASSEMBLE TO FORM A FINAL COMPONENT. 
• THE FEATURES LIKE DOG HOUSE, RIBS, SCREW BOSS, LOCATORS, HEAT STAKES AND FLANGES ETC., ALL THESE ARE CONSTRUCTED BY FOLLOWING DESIGN RULES.

• EXPLANATION-

1.SCREW BOSS- THES ARE THE PROTRUSIONS ON THE PLASTIC COMPONENTS WHICH ASSIST DURING ASSEMBLY OF COMPONENTS USING SCREWS.

2.RIBS- THESE ARE THE THIN WALL LIKE STRUCTURES WHICH PROVIDE SUPPORTS FOR THE PLASTIC COMPONENTS.

3.DOG HOUSE- THESE ARE THE SUPPORTING FEATURES FOR OTHER FEATURES TO REDUCE THE SINK MARKS BY INCREASING THE HEIGHT OF OTHER FEATURES, IT ALSO ACTS AS A CLAMPING FEATURE BY                                   ATTACHING WITH PUSH PIN CLIP DURING ASSEMBLY WITH SHEET METAL COMPONENTS.

4.LOCATORS- THESE FEATURES ARE USED TO RESTRICT THE DEGREE OF FREEDOM OF AN PLASTIC COMPONENT. THESE ARE OF TWO TYPES 1. 2 WAY LOCATORS 2. 4 WAY LOCATORS.

                        THEY ALSO HELPS IN GUIDING THE PLASTIC COMPONENT DURING ASSEMBLY WITH THE SHEET METAL PART.

5.HEAT STAKES- THESE FEATURES ARE USED TO ATTACH TWO PLASTIC COMPONENTS TOGATHER BY MELTING THE TIP OF THE HEAT STAKES AS SHOWN IN BELOW IMAGES.

6.FLANGES- THESE ARE CREATED AS PER THE MASTER SECTIONS AND THESE PREVENTS THE SLIDING OR SLIPPING OF TWO PLASTIC COMPONENTS WHICH IS TO BE ASSEMBLED.

                      THE FLANGES ALSO HELP IN GETTING GOOD FINISH AND PREVENTS THE GAP BETWEEN THE COMPONENTS AFTER ASSEMBLY.

CONSTRUCTION OF ENGINEERING FEATURES-

1.DOG HOUSE-

LET US CONSIDER AN EXAMPLE OF CONSTRUCTION OF DOG HOUSE ON MAP POCKET.

THE STEPS TO CONSTRUCT THE DOG HOUSE ARE AS FOLLOWS-

• EXTRACT THE SURFACE FROM THE CLASS A, PLACE A POINT ON THE SURFACE AND CREATE A PLANE AS SHOWN IN ABOVE IMAGES.

• CONSTRUCT THE SKETCH AS SHOWN IN ABOVE IMAGES.

• EXTRUDE THE SKETCH BY FOLLOWING DESIGN RULES AS SHOWN IN ABOVE IMAGES.

• DRAW THE SKETCH AND EXTRUDE IT AS SHOWN ABOVE.

• DRAW THE SKETCH, EXTRUDE THE LINE AND TRIM TO CREATE A CLOSED DOG HOUSE AS SHOWN IN ABOVE IMAGES.

• THE SKETCH IS DRAWN AND PADED FOR REQUIRED THICKNESS. THE PLANE IS OFFSETED TO REQUIRED HEIGHT AND THICKENED, BOTH HORIZONTAL AND VERTICAL MEMBERS ARE ADDED TOGATHER.
• SIMILARLY THE OUTER BODY IS ALSO THICKENED AND UNION TRIMED AS SHOWN IN ABOVE IMAGES. 

• THE PLANES ARE OFFSETED AND TRIMMED TO OBTAIN THE SURFACE AS SHOWN IN ABOVE IMAGES.
• THE TRIMMED SURFACE IS SOLID SPLIT WITH THE DOG HOUSE AS SHOWN IN ABOVE IMAGES.

• THE SKETCHE IS PADDED AND REMOVED FROM THE DOG HOUSE TO OBTAIN THE DOG HOUSE AS SHOWN IN ABOVE IMAGES.

• AND FINALLY AFTER PROVIDING THE RADIUS AND DRAFT ANGLES ALONG BOTH THE TOOLING AXIS AND SIDE CORE AXIS THE DOG HOUSE IS AS SHOWN IN THE ABOVE IMAGES.

• SIMILARLY THE DOG HOUSE IS CONSTRUCTED ON ALL THE PART AND ASSEMBLED ON TO IT.

2.HEAT STAKES-

• HERE THE HEAT STAKES ARE CONSTRUCTED BY TAKING THE REFRENCE FROM THE MASTER SECTIONS, IF THE MASTER SECTIONS ARE NOT AVAILABLE THE IT IS CONSTRUCTED BY FOLLOWING DESIGN RULES.
• THE LOCATION OF HEAT STAKES ARE ALSO TAKEN FROM THE MASTER SECTIONS OR IT CAN ALSO BE LOCATED BASED ON DESIGNER POINT OF VIEW.

• THE REFRENCE POINT IS TAKEN FROM THE MASTER SECTION AND ISOLATED. 
• THE SKETCH IS DRAWN FROM THE INPUT PROVIDED WHICH IS THEN PADDED TO OBTAIN THE HEAT STAKES AS SHOWN IN ABOVE IMAGES. 

• SIMILARLY THE HEAT STAKES IS LOCATED ON DIFFERENT LOCATIONS BASED ON DESIGNER POINT OF VIEW AND REFRENCE FROM MASTER SECTIONS.

3.LOCATORS-

• THE SKETCH IS DRAWN AS PER THE REQUIRED DIMENSIONS AND PADDED FOR THE REQUIRED THICKNESS.
• NECESSARY RADIUS, DRAFT AND CHAMFER IS PROVIDED TO OBTAIN 4 WAY AND 2 WAY LOCATOR AS SHOWN IN ABOVE IMAGES.

• SIMILARLY THE LOCATORS ARE PLACED ON ALL THE PARTS BASED ON DESIGNER POINT OF VIEW.

STEP 10: FLANGE CREATION

• THE FLANGES ARE CREATED AS PER THE MASTER SECTIONS. IN SOME CASE WHERE THE MASTER SECTIONS ARE NOT AVAILABLE THEN FLANGES ARE CREATED AS PER DESIGNER POINT OF VIEW.

• HERE THE POINTS ARE CREATED BY TAKING THE REFRENCE FROM THE MASTER SECTION WHICH IS THEN ISOLATED.
• THE CLASS C SURFACES IS EXTENDED AND THE EXTRUDED SURFACES FROM THE LINES BOTH ARE TRIMMED TO GET THE SURFACES WHICH IS AS SHOWN IN ABOVE IMAGES.

• THESE FLANGES ARE THICKENED AND SOLID SPLIT IS USED TO OBTAIN THE FLANGE OF REQUIRED DIMENSIONS.
• NECESSARY EDGE FILLETS AND DRAFTS ARE PROVIDED.

• THE SKETCH IS CREATED AND PADDED WHICH IS THEN REMOVED FROM THE FLANE USING BOOLEAN OPERATIONS AS SHOWN IN ABOVE IMAGES.
• THE DRAFT ANGLE IS ALSO PROVIDED FOR THE HOLE. THE HOLE IS CREATED IN SUCH A WAY THAT A SMALL CLEARENCE IS PROVIDED FOR THE FITMENT OF THE HEATSTAKES. 

SIMILARLY THE FLANGES ARE CREATED ON VARIOUS LOCATIONS BASED ON THE REQUIREMENT IN THE DESIGN AND AS PER MASTER SECTIONS WHICH ARE AS SHOWN BELOW.

STEP 11: DRAFT ANALYSIS -

THE STEPS TO BE FOLLOWED FOR THE DRAFT ANALYSIS ARE AS FOLLOWS-

• CHANGE THE SHADING TO MATERIAL AND SELECT OK BEFORE PROCEEDING TO THE DRAFT ANALYSIS.

• CLICK ON INSERT, SELECT FEATURE DRAFT ANALYSIS IN ANALYSIS AS SHOWN IN ABOVE IMAGES.

• SELECT THE COMPASS TOOL AS SHOWN IN THE ABOVE IMAGES.

• PLACE THE COMPASS ON THE TOOLING AXIS AND LOCK THE DRAFTING DIRECTIONS AS SHOWN IN ABOVE IMAGES.

• NOW SELECT THE COMPONENT AND THE RESULTS ARE OBTAINED IN THE FORM OF COLOUR CODES.

SIMILARLY THE DRAFT ANALYSIS IS CARRIED ON ALL THE COMPONENTS AND ENGINEERING FEATURES WHICH ARE AS SHOWN IN BELOW IMAGES.

1.DOG HOUSE-

2.HEAT STAKES-

3.LOCATORS-

4.FLANGES-

5.ARM REST-

6.MAP POCKET-

7.LOWER MAP POCKET-

8.LOWER SUBSTRATE-

STEP 12: PARTING LINE

• IT CAN BE DEFINED AS THE LINE ALONG THE COMPONENT WHICH SEPERATES THE CORE AND CAVITY SIDE OF THE TOOL.
• IT CAN ALSO BE DEFINED AS THE LINE ON THE COMPONENT ALONG WHICH THE FLASHES ARE FORMED.
•  

THE IMAGES OF PARTING LINE FOR THE COMPONENTS ARE SHOWN BELOW-

STEP 13: ORIENTATION VIEWS

THE ISOMETRIC, FRONT, SIDE AND TOP VIEWS ARE AS SHOWN BELOW-

ASSEMBLY OF PLASTIC DOOR TRIM PANEL WITH SHEET METAL (DOOR)

• THE PLASTIC DOOR TRIM PANEL IS ATTACHED TO THE SHEET METAL DOOR WITH THE HELP OF DOG HOUSE AND PUSH PIN/CLIP.

                                                                                                                                           

• THE DOG HOUSE IS ATTACHED WITH THE PLASTIC PUSH PIN/CLIP AS SHOWN IN ABOVE IMAGES.
• THESE ASSEMBLY OF DOG HOUSE AND PUSH PIN IS USED TO ASSEMBLE THE PLASTIC DOOR TRIM PANEL WITH THE SHEET METAL PART OF THE DOOR WHICH GETS LOCKED DUE TO PRESENCE OF TAPER AT THE ENDS AS SHOWN IN ABOVE IMAGES.