Week 12- Final project

Aim: In this project we create the door trim panel Components that is (Lower substract,Arm rest, Bottle holder, map pocket) with the necessary input surfaces provided and generating the necessary B side features ( heat stakes, 4 way locators, Dog houses, push clips, Ribs, screw bosses etc) thereby  assemble  the individual components of the door trim by providing proper constraints  there by performing the proper draft analysis using catia V5  software

Objective:

The main objective is to create the individual components of the door trim with input class A surface provided and generate the class B and class C surface and produce the solid surface body out of it and perform the proper draft analysis with required draft angle of 3 degrees for the body and continue the procedure for the remaining components .Then start creating the B side features of the components by following the reference of the master sections  provided and perform the draft analysis with an input draft angle of .5 degrees and assemble the components to for the final door trim panel on the assembly workbench by providing necessary constraints using catia V 5 s

Procedure followed for the creation of the components:

Analyse the input surface  provided

Class A surface as input surface

Tooling axis creation

Draft analysis of class A surface

Class B surface creation

Class C surface creation

Solid surface body generation

Draft analysis of the solid body

creating the B side features

Draft analysis of the solid body along with the B side features .

Class A surface:

Class A surface is an aesthetic surface which is visible for the customer in the component

Class B surface:

Class B surface is an engineering surface where the B side features of the components like heat stakes, screw bosses, Ribs, doghouses are situated

Class C surface:

Class c surface lies as an intermediate surface between the class A and the class B surface that means it generally accommodate the thickness of the whole plastic component

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.

                         

Arm rest design

In the front of the car, a central armrest, which commonly folds away based on user preference, will also often include a storage compartment and sometimes even cup holders. Some also provide the location for controls for non-essential functions of the vehicle, such as climate control or window motors.

For the Arm rest design the input class a surface provided is

                                   

To check whether the surface has any open boundaries use the boundary feature then we can identify that there is an open patch or the surface which we need to work on This is the open patch we got from the boundary feature

After complete working on the open patch check the boundary of the surface to confirm whether there may be any possibility of the open surfaces .Then name the obtained surface as the class A surface and start working on it.

Tooling axis creation:

In case of the arm rest we generally deploy the bisection method for creating the tooling axis , that is first we need to create a plane and form an intersection of the surface and generate the two lines from the intersection and there by creating a line by using the bisection method

                                   

Draft analysis of the class A surface:

Once the creation of the tooling axis is done perform the draft analysis of the class A surf ae whether all the surfaces of the class A is clearing the draft analysis or not

General draft angle provided on the plastic engineering component is 3 degrees

                                   

Here some of the surfaces of the class a surface cannot be able to clear  the draft analysis with respect to the main tooling axis so , either you should report to the concerning team to update the draft on the uncleared  surfaces or continue it.

Generating of the class B surface

For the class B surface generation refer to the master section provided to measure the thickness of the plastic component then offset the class A surface to an extend of 2.5 mm thickness beneath the class A surface

                                    

Extrapolate then class b edges to an extent to form the proper trim with the class a & C join

Generating the class C surface:

For the class C surface generation we use the class A surface  as an reference and follow the draft with respect to the reference surface and the main tooling axis

                                    

Draft analysis of the final solid body :

After generating the final closed body perform the draft analysis with a draft angle of 2.98 ~3 degrees

And examine whether all the required surfaces are clearing the draft with respect to the main tooling axis of any draft applied surfaces can’t  be able to clear the draft analysis write a report mentioned what might be the reason for the surfaces not clear in the draft analysis and suggest the appropriate solution if else.

Lot of the surfaces can able to clear the draft analysis but the surfaces which we mention in the class a surface draft analysis they have created then problem while clearing the draft in the final solid surface

here in the case of the class c surfaces some the surfaces have a lower draft or the draft of negative type because if they create along with respect to the correct sweep followed the quality of the surface obtained is not that much good it might be twisty or not uniform so we continue with the negative draft.

                                    

Lower subtrate:

In case of the door lower subtrate after examining the provided input surface we can able to detect a projection or an extension so we don’t need it for any further so, create a line and split the unnecessary surface

                                    

Tooling axis creation:

Extract the surface from the class A where the surface is entirely visible and easy for the manufacturing by viewing the surface in different orientations

Now create a point at the middle At 0 coordinates and create a line in point and direction method and the create line is our main tooling axis.

                                    

Draft analysis of the class A surface:

Perform the draft analysis on the class A surface  to check whether all the surface are clearing the draft of 3 degrees with respect the tooling axis we create then continue with the model or if you notice any flaws notice them with the class A team to rectify or else continue with the class B surface creation.

                                      

Creation of class B surface:

In case of the lower substract offset the class A surface to a value of 2.5 mm beneath the class A surface then extrapolate the class B surface which would help to make the final trim with the class A and C combined surface.

Creation of class C surface :

When the surface of the class C is parallel to the tooling axis then make use of the sweep with respect to the draft Direction to an angle of 3 degrees and the surface need to be outside the class A surface when seen from the normal direction with respect to the main tooling axis. And if the class C surface which need to create is perpendicular to the tooling axis then make the sweep with the reference surface With 90 degrees or with 87 degrees.<!--[endif]-->

                                        

Draft analysis of the solid body:

Preform the draft analysis on the solid body with a draft angle of 3 degrees and see the results

These type of deviation in the draft angle on the surface is mainly due to the quality of the class A surface provided , if we manage to provide the correct draft it will lead to the distortion of the class c surface which leads to the difficulty in manufacturing the component so, report the above draft analysis of the solid body to adopt or alter the proper changes in the class A surface team.

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Map pocket design:

Map pocket is the sub element situated right at the hub of the lower substract of the door trim panel . The processs illustrated is same as the prevous components first, we need to check the boundary of the given input surface whether there might have any open patches or else protrude the input surface as the required class A surface

The provided input surface is

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Tooling axis creation:

In case of the map pocket the we extract the surface in the Y direction orientation and use the point - direction to generte the tooling axis of the map pocket.

Draft analysis of the class A surface:

Once the tooling axis is create analyze the draft for the class A surface with a draft angle of 3 degrees

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So, its perfectly clearing the draft of 3 degrees with the generated tooling axis

Class B surface creation:.

Now step forward to create the class B surface deploy the 2.5mm offset of the class A surface to generate the class B surface beneath the class A surface

Class C surface creation:

Now create the class C surfcae which is an intermediate surface between the class A and the class B surface generally like a fill between the  two surfaces created with the help of the sweep feature with a draft of 3 degrees

along the tooling axis direction and with a draft of 90 degrees along the reference surfcae sweep

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Draft analysis of the solid body:

Now perform the draft analysis with a draft angle of 3 degrees on the solid body

The results obtained are

Almost all the surfaces are clearing the draft of 3 degrees along there B side but some of the surfaces that leads to a lower draft or the negative draft mainly these issues rise when there is an issue with the class A surface .Here the class a draft is perfect but the curvature of the class A surface at the corner edges is not that much good, so during the class C surface generation the class c might not be that perfect to clear the draft angle of 3 degrees if possible to manage the surface to clear the draft the quality of the curvature formed at the corner or at the irregular curvature is impossible to manufacture So, make a report regarding issues due to the curvature defects and report the draft defects to the class A team so they will make the necessary adjustments in the class A surface if necessary

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Bottle holder:

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Lower subtract attachment features:

Based on the master sections provided for the for the input surface of the lower substrate it indicates that the heat stakes are positioned on the surface

Following the master section wee need to create the heat stakes on the lower subtract B side

Heat stakes :

Process for heat stakes assembly:

In thermal staking, also referred to as “heading or riveting”, the controlled flow of the molten plastic is used to capture or retain another component, usually of a different material. Thermal staking provides an alternative to welding when the two parts consist of dissimilar materials which cannot be welded or when simple mechanical retention of one part relative to another is adequate .

The most commonly used application involves the attachment of metal to plastic. A hole in the metal part receives a pre-moulded plastic boss. The thermal tip contacts the boss and creates localized heat. As the boss melts, the light pressure from the horn forms a head to a shape determined by the horn tip configuration. When the heat is terminated, the plastic material solidifies and the dissimilar materials are fastened together.

So taking the references from the master section here we need to make a note of that whenever we take the reference from the master section the referenced element should be isolated from the master section

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3. Dog house creation:

DOGHOUSE- Doghouse is an engineering feature used in the plastic trim design which helps to remove sink marks formed on Class-A surface while creating attachment feature on Class-B surface. Doghouse is a supporting feature, other features like locators, heat stakes, pushpins are mounted on top of doghouse for fixing and assembly purpose. Doghouses are subjected to draft analysis to prevent breakage of the component during ejection from the mould.

Here I has used a 15*15 dog house padded to a height of 40mm.

PUSH PINS- Push pins are used for joining one component to another . These are basically attached to the doghouse. For creating the push pins the following reference was taken for dimensions.

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FINAL DOOR TEIM PANEL: