Week 12- Final project

 Development of a Door Trim panel

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 an 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

Product Life cycle

On a broad spectrum, the automotive design process can be split up into four stages: 

1. Concept
2. Sketch
3. Class A Surface (CAS)
4. Computer-Aided Design (CAD)On a broad spectrum, the automotive design process can be split up into four stages: 
   1. Concept
   2. Sketch
   3. Class A Surface (CAS)
   4. Computer-Aided Design (CAD) 

An automotive vehicle concept is first hypothesized or envisioned by an artist, designer, or engineer, which is then sketched onto a paper. Once an idea is approved, it moves on to the computer where it is rendered in 2D.  

Then, the Class A Surfaces are built. This is followed by a complete 3D CAD modelling of the automotive vehicle, including photorealistic renders, which later goes into mass production.

On a higher level, the product development process can be summarized as follows: 

1. Styling theme and approval CAS
2. Preliminary design
3. Preliminary analysis
4. Final style approval
5. Detail design
6. Verification
7. Development
8. Prototype build
9. Design validation
10. Plot production
11. Launch and mass production

Concept Sketch: Pre hand drawing done on a paper later converted to styling Class A which is basically done by software like ALIAS.

Design validation determines whether the design fulfills the intended purpose

Feasibility check is to determine the practicability of a design.

Concept validation is the stage of validating the design and possibility.

DESIGN LIFE CYCLE

It Involves

Concept sketches

Class A creation

Clay modeling

NPD CAD

Concept sketch:

Class-A (or 'Strak') is a term used in specifically in automotive design. It describes the final production surface data for the aesthetic parts of the car. 

Before mass production any corrections will be corrected.

Class A and clay modeling are inter related. Clay model is the one to one model of vehicle both interior and exterior would be made for realistic display.

NPD CAD – New product development is where the designing parts for assembly with dimensions takes place.

Materials details

Interior Trims are manufactured by Poly propylene (PP), Acrylonitrile butadiene styrene (ABS), Poly vinyl chloride (PVC).

Since plastic in light in weight, economic effectiveness wide variety of plastic are used. It also gives good aesthetic surface.

CLASS A CREATION

From the given Input the respective class A class A surface are created by joining the surfaces. Check for continuity of the surface.

Tooling axis Creation

Tooling axis is the direction in which the mold opens and closes. Also the areas which need to be drafted. To find the tooling axis analyze the part like walls and find the possible tooling axis .Tolling axis can also be created by bisecting method.

Now for the door arm the tooling axis is created in Z direction. The slider axis is also created for the purpose drafting. Door arm is taken as two parts.

For Lower substrate the tooling axis is taken in Y direction.

For Map pocket in y direction.

Dog house: Dog house is an engineering feature used in plastic trim design which is used as a supporting feature. Other features like locator are mounted on them to increase strength. They prevent breakage of the component during ejection.Ribs are given for dog house. Push clip is mounted on the dog house .

the sketches are drawn with positiones and iso constrained.