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.

Objectives :-  

• To create individual tooling axis for the parts and perform draft analysis on the class A surface
• To create the class B and class C surfaces from the given class A surface
• To form a solid geometry by combining all the surfaces
• To decide an attachment strategy for the part and create engineering features in reference from the master section provided
• To perform draft analysis on the solid part model with all engineering features
• To assemble all the components togehter to obtain the final trim

Given Data :- 

• Class A Surface for Door Trim Panel -

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. 

Door Trim Components:

• Arm Rest
• Bottle Holder
• Lower Substrate
• Map Pocket
• Push Pin

B-Side Engineering Features:

• Heat Stakes
• Ribs
• Locators
• Dog-House

•  1. Arm Rest:

  • Class A Surface: 

  Class A is an aesthetic surface with the highest quality finish. Most Class A Surfaces for an Automotive Component are made using 'Autodesk-Alias' based on the final Concept-Sketch.

  All Class A surfaces should have 'Curvature-Continuity', meaning the continuity between the surfaces should share the same boundary. It is taken as a reference by the Automotive Plastic Designer to create 'Class B' and 'Class C' Surfaces.

  • Class B Surface: 

  The Class B Surface resides below the Class A Surface at a certain thickness. It is created using Engineering Principles that consist of all the necessary features such as Ribs, Bosses, Snaps, etc. This surface isn't visible to the observer from the outside. 

  • Class C Surface: 

  The Class C Surface is the surface created between the Class A and Class B surfaces to join them with each other.

  Now, we will begin by checking the State of Connectivity for the Class A Surface and ensure that there are no gaps between the surfaces as all the surfaces should be joined well together with each other and shouldn't consist of any discontinuities between them.

  

  Draft analysis for the given CLASS-A surface

  The Draft Analysis is a command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on colour ranges identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values.

  Draft analysis is done after determining the tooling axis, draft analysis is used to check whether the minimum draft (3 degrees) is maintained or not.

  • Procedure for performing the draft analysis are as follows
  • Change the view mode of the component to be in customized parameter mode and then select the shading mode as materials.
  • Then open the featured draft analysis tool from the insert menu.
  • Then click on use the compass to define the current drafting direction without activation the compass and then activate the compass in the dialogue box drag and align the compass on the Tooling axis.
  • Then lock the draft direction and perform draft analysis by clicking on the component.
  • The green colour shows the positive daft tooling direction and the given surface passes the draft analysis.
  • Click on the analysis under the running point to check the draft analysis on the individual faces. It shows how much draft on specific points when we move the cursor point.

    Procedure for creating the tooling axis

    Tooling axis represents the opening and closing of the mold core and cavity during the manufacturing of the components. A plastic product designer should consider the best tooling direction to cutdown the cost of the component very less.

    Method opted for creating tooling axis for the door handle

    • Check the best tooling direction for the given surface.
    • We can find out the best tooling direction by cross checking all the three axes.
    • Here we can find out that the best tooling direction for the Arm rest  class-A surface is along Z-axis direction.

Creating tooling axis   

•  We should create a Dummy tooling axis first by creating point and line.
• Extract the existing class A surface and create a dummy tooling axis for reference.Highlighted megentha  colour is main tooling axis.

SURFACE-B CREATION

Class-B surface means thickness of a part it is not visible and is inside part. In other words, Class-B surface is a surface below a certain thickness from the class-A surface. This is the surface that contains engineering aspects of a model.

• Offset the class-A surface to 2.5mm inward direction

Creation of C Surface

• Surface that joins class-A and class-B surfaces is class-C surface. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled
• Since it is a  class-A surface with sharp corners, we cannot simply create the class-A boundary curve and sweep it at one shot.
• Hence, we need to create smaller boundary and then create sweep,Multi section surface.
• If the surface is perpendicular to the tooling axis we have to provide 3 degree draft with reference to the tooling direction.
• 

Flange creation using master section

• In case of te door arm rest we need to folow the master section provided for the flange creation
• The thickness of the flange is equal to the thickness of the plastic component that is 2.5 mm
• To use the master section as reference and create the sketch and generate the surface, then make ticken surface.
• The draft provided is 0.5 deg
• Apply requierd fillets on all the sharp edges.

  2.  Bottle Holder

Bottle Holder Class A Surface:

Creating tooling axis   

•  We should create a Dummy tooling axis first by creating point and line.
• Extract the existing class A surface and create a dummy tooling axis for reference.Highlighted megentha  colour is main tooling axis.

Draft analysis for the given CLASS-A surface

The Draft Analysis is a command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on colour ranges identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values.

Draft analysis is done after determining the tooling axis, draft analysis is used to check whether the minimum draft (3 degrees) is maintained or not.

• Procedure for performing the draft analysis are as follows
• Change the view mode of the component to be in customized parameter mode and then select the shading mode as materials.
• Then open the featured draft analysis tool from the insert menu.
• Then click on use the compass to define the current drafting direction without activation the compass and then activate the compass in the dialogue box drag and align the compass on the Tooling axis.
• Then lock the draft direction and perform draft analysis by clicking on the component.
• The green colour shows the positive daft tooling direction and the given surface passes the draft analysis.
• Click on the analysis under the running point to check the draft analysis on the individual faces. It shows how much draft on specific points when we move the cursor point.

SURFACE-B CREATION

Class-B surface means thickness of a part it is not visible and is inside part. In other words, Class-B surface is a surface below a certain thickness from the class-A surface. This is the surface that contains engineering aspects of a model.

• Offset the class-A surface to 2.5mm inward direction.
• After offset ,There is no patches in the fillet area.

Creation of C Surface

• Surface that joins class-A and class-B surfaces is class-C surface. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled
• Since it is a  class-A surface with sharp corners, we cannot simply create the class-A boundary curve and sweep it at one shot.
• Hence, we need to create smaller boundary and then create sweep,Multi section surface.
• If the surface is perpendicular to the tooling axis we have to provide 3 degree draft with reference to the tooling direction.

Final A C B

Flange creation using master section

• The thickness of the flange is equal to the thickness of the plastic component that is 2.5 mm
• To use the master section as reference and create the sketch and generate the surface, then make ticken surface.
• The draft provided is 0.5 deg
• Apply requierd fillets on all the sharp edges.

3.Lower Substrate

 Lower Substrate class A Surface

Creating tooling axis   

•  We should create a Dummy tooling axis first by creating point and line.
• Extract the existing class A surface and create a dummy tooling axis for reference.Highlighted megentha  colour is main tooling axis.

SURFACE-B CREATION

Class-B surface means thickness of a part it is not visible and is inside part. In other words, Class-B surface is a surface below a certain thickness from the class-A surface. This is the surface that contains engineering aspects of a model.

• Offset the class-A surface to 2.5mm inward direction.
• After offset ,There is no patches in the fillet area.

Creation of C Surface

• Surface that joins class-A and class-B surfaces is class-C surface. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled
• Since it is a  class-A surface with sharp corners, we cannot simply create the class-A boundary curve and sweep it at one shot.
• Hence, we need to create smaller boundary and then create sweep,Multi section surface.
• If the surface is perpendicular to the tooling axis we have to provide 3 degree draft with reference to the tooling direction.

FINAL A C AND B

closed body

B-Side Engineering Features:

• Dog-House
• Heat Stakes
• Ribs
• Locators

DOG HOUSE DESIGN:

Dog house is an engineering feature used in the plastic trim design. Dog houses are used as supporting features. Sometimes other engineering features like boss; locators, etc. are mounded on them to increase their dimension and strength.  Dog house and other engineering Features are built on final close solid body.

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

4 Way Locators:

4-way  locators mean you have to prevent the movement at 2 axes translate and rotational  (+X, -X, +Y and -Y) on the plane. Generally, you have cylindrical pin on the fixture and circular hole at workpiece part.

4. Map pocket

Map pocket class A Surface

Creating tooling axis   

•  We should create a Dummy tooling axis first by creating point and line.
• Extract the existing class A surface and create a dummy tooling axis for reference.Highlighted megentha  colour is main tooling axis.

SURFACE-B CREATION

Class-B surface means thickness of a part it is not visible and is inside part. In other words, Class-B surface is a surface below a certain thickness from the class-A surface. This is the surface that contains engineering aspects of a model.

• Offset the class-A surface to 2.5mm inward direction.
• After offset ,There is no patches in the fillet area.

Creation of C Surface

• Surface that joins class-A and class-B surfaces is class-C surface. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled
• Since it is a  class-A surface with sharp corners, we cannot simply create the class-A boundary curve and sweep it at one shot.
• Hence, we need to create smaller boundary and then create sweep,Multi section surface.
• If the surface is perpendicular to the tooling axis we have to provide 3 degree draft with reference to the tooling direction.

Class A B and C

Closed Surface

Flange creation using master section

• The thickness of the flange is equal to the thickness of the plastic component that is 2.5 mm
• To use the master section as reference and create the sketch and generate the surface, then make ticken surface.
• The draft provided is 0.5 deg

5.PUSH PINS-