Week 12- Final project

NOTE: I have Attached the Report, Photos and CADpart in the Attachment

Week 12- Final project

AIM:

To develop the Door Trim panel

OBJECTIVE:

• Creation of CAD model considering following inputs as like in OEM and tier1 companies

1. a) Class A surface
2. b) Nominal thickness : Refer master sections
3. c) Attachment strategy : 

• Find a attachment strategy for the door panel complete work.
• Use Push pin with Dog house for Lower substrate – Door panel attachment
• Use heat stakes for part to part attachment

Output required:

• Create thickened part using master section for reference
• Create the mounting features as per design guidelines in the industry and with master sections
• Apply material details : 
• Draft analysis & Tooling analysis
• Creation of parting lines and check tooling feasibility

SOFTWARE USED : CATIA

Let us look at how we have designed

INPUT:

CAD DATA is downloaded and Opened with CATIA.

TOOLING AXIS:

Tooling axis is defined as such all the features of the part can be manufactured easily. so here we followed the below steps to create the tooling axis.

• Tooling Axis created for the parts.
• Different ways of tooling axis creation is followed in OEM.
• Bisecting method, point and direction are methods used here.
• Side core axis is also defined when needed.
• These are the photos of the tooling axis.
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• DRAFT ANALYSIS:

  • Draft is done on the Class A surface of the parts 
  • Change it to material in customise view.
  • Click the Draft analysis tool and click the surface and align the compass to tooling axis.
  • 3 degree is the clearing angle
  • So here is photo of cleared (Green) draft.
  • Few parts are defective (mentor rahul said) so those sections not cleared the 3 degree. Kindly consider
  • Here are the photos
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  B SURFACE:

  • B surface is created by using the given Class A surface.
  • Apart complicated face join other faces.
  • Offset it to 2.5mm beneath the Class A.
  • Create boundry and Create MSS, Extrapolate for the rest of the sections.
  • Trim the extrapolates and join if needed.
  • Hence we have created the B surface.
  • 

  • C SURFACE:

    • The outer edge of the Class A surface is taken as reference boundry.
    • Sweep is made with reference to tooling axis with draft.
    • Join the sections and create the C Surface.
  • 

  • FINAL TRIM:

    • Join A and C surface.
    • Trim with the B surface.

    • DRAFT ANALYSIS:

      • Draft is done on the Class A surface. 
      • Change it to material in customise view.
      • Click the Draft analysis tool and click the surface and align the compass to tooling axis.
      • 3 degree is the clearing angle
      • So here is photo of cleared (Green) draft.

      NOTE: Few sections are not clearing the draft analysis. Mentor Rahul said that it is Class A defective so it can be carry forwarded. Kindly consider

    • PARTING LINE
    • 
    • 
    • Here are the photos of the door trim

    • ASSEMBLY:

      • We then create a product file
      • Add the components
      • Give constraints and finish the assembly
      • 

    • RESULT:

      Thus we have developed the Door Trim panel