Week 12- Final project
AIM:-
TO DESIGN VEHICLE INTERIOR DOOR TRIM USING CATIA V5 WITH GIVEM CLASS A SURFACE AND MASTER SECTION. ALSO, TO CREATE ENGINEERING ATTECHMENT FEATURES AS PER DESIGN RULES AND CHACKE FOR PRODUCTION FEASIBILITY.
OBJECTIVE:-
- TO CREATE CLASS B & C SURFACE USING CLASS A SURFACE AS REFERANCE.
- CREATING SOLID MODEL USING CLOSED SURFACE
- CREATING ATTECHMENT FEATURES ON B SIDE
- CREATING TOOLING AXIS
- PERFORMING DRAFT ANALYSIS
- CREATING PARTING LINE FOR BEST PRODUCTION FEASIBILITY
INTRODUCTION:-
DOOR TRIMS ARE ASTHETIC PART OF CAR WEHICLEWHICH CONTAINS SOME CONTROLES AND HELPS TO PROVIDE COMFORT TO PASENGERS. ALSO, IT HELPS TO HIDE ALL THE ENGINEERING WORK (WELDING, HOLES, WIRIN) PERFORMED ON DOOR TO PROVIDE BATTER ENVIRONMENT TO PASENGERS.
DOOR TRIMS CONSISTS OF SOME PARTS LIKE UPPER DOOR SUBSTRATE, LOWER DOOR SUBSTRATE, ARM REST, DOOR GARNISH (DECORATIVE PART TO PROVIDE MORE ESTHATIC LOOK), MAP POCKET.
PROCESS FOLLOWED TO CREAT PLASTIC PRODUCT:-
- CLASS A SURFACE VISUAL INSPECTION (WETHER SURFACE IS JOINED TOGETHER OR NOT)
- TOOLING AXIS CREATION
- DRAFT ANALYSIS FOR CLASS A SURFACE
- CLASS B SURFACE CREATION
- CLASS C SURFACE CREATION
- CLOSED BODY CREATION
- DRAFT ANALYSIS FOR SOLID BODY
- ATTECHMENT FEATURES CREATION
- PARTING LINE CREATION
GIVEN PART DATA:-
ALL THE PART GIVEN WITH CLASS A SURFACE AND MASTER SECTION
CLASS A SURFACE:-
CLASS A SURFACE IS THE SURFACE VISIBLE TO PASENGERS CONSIST OF HIGH QUALITY TEXTURE AND MOST ASTHETIC DESIGN, CLASS A SURFACE IS DEVELOPED BY CLASS A SURFACE DESIGNER IN COMPUTER AIDED SOFTWARE LIKE AUTODESK ALIAS.
MASTER SECTION:-
MASTER SECTION IS LINE REPRESENTATION AT SPECIFIC INSTINCS ON CLASS A SURFACE IN ORDER TO PROVIDE REFERENCE TO PLASTIC PRODUCT DESIGNER FOR PART THICKNESS, ATTECHMENT FEATURE LOCATIONS.
GIVEN PARTS:-
- DOOR LOWER SUBSTRATE
- ARM REST
- PAM POCKET UPPER SIDE
- MAP POCKET LOWER SIDE
CLASS A SURFACE OF ALL THE GIVEN PARTS:-
DOOR LOWER SUBSTRATE
ARM REST
MAP POCKET UPPER PART
MAP POCKET LOWER PART
TOOLING AXIS:-
TOOLING AXIS IS THE AXIS IN WHICH DIRECTION CORE AND CAVITY OPENS AND CLOSES,
A DESIGN ENGINEER CHECKS FOR THE BEST TOOLING DIRECTION ON CLASS A SURFACE AND ALSO USES THE SAME AXIS TO PROVIDE ALL THE NECESSARY DRAFT IN DIRECTION OF TOOLING AXIS SO THAT FINAL PRODUCT CAN BE EJECTED EASILY FROM THE MOLD.
TOOLING AXIS OF DOOR LOWER SUBSTRATE:-
DOTTED LINE HIGHLITED IN CYAN COLOR IS MAIN TOOLING AXIS
TOOLING AXIS OF ARM REST
DOTTED LINE HIGHLITED IN DARK BLUE COLOR IS MAIN TOOLING AXIS
ARM REST NEEDS TO BE MANUFECTURED USING SEVERAL SIDE CORES, TO ANALYSE SIDE CORE FEASIBILITY CREATED SIDE CORE AXIS.
DOTTED LINES IN LIGHT BLUE COLOR ARE SIDE CORE AXIS
TOOLING AXIS FOR MAP POCKER UPPER PORTION
DOTTED LINE HIGHLITED IN PURPLE COLOR IS MAIN TOOLING AXIS
TOOLING AXIS FOR MAP POCKET LOWER PORTION
DOTTED LINE HIGHLITED IN YELLOW COLOR IN MAIN TOOLING AXIS
DRAFT ANALYSIS FOR CLASS A SURFACE:-
THIS TECHNIQUE IS USED TO CHECK WETHER THE PART WE DESIGNED IS MANUFECTURABLE OR NOT AS PER THE DRAFT CONDITION, IN AUTOMOTIVE DRAFT ANALYSIS IS PERFORMED TO MAKE SURE THE TOOLING AXIS IS CORRECT AND THE PART WHICH IS GOING TO DESIGN CAN BE EASILY REMOVED FROM THE MOLD.
NOTE: THE PART HIGHLITED IN GREEN COLOR IS HAVING POSITIVE DRAFT
THE PART HIGHLITRD IN RED COLOR IN HAVING DRAFT BETWEEN ZERO TP SPECIFIEC DRAFT ANGLE
THE PART HIGHLITED IN BLUE COLOR IS HAVING NEGATIVE DRAFT
THE DRAFT ANGLE IS GIVEN OF 3 DEGREE AS PER INDUSTRY NOMES
DRAFT ANALYSIS OF DOOR LOWER SUBSTRATE
DRAFT ANALYSIS OF ARM REST
THE ARM REST PART IS HAVING COMPLAX SHAPE SO, FOR MANUFECTURING THIS PART IT REQUIRES MULTIPLE CORES AND CAVITY, FOR THIS MULTIPLE CORE DIFFERENT TOOLING AXIS IS GIVEN AND DRAFT ANALYSIS PERFORMED ON ALL THE SIDE CORE AXIS ALONG MAIN TOOLING AXIS.
DRAFT ANALYSIS IN MAIN TOOLING DIRECTION
DRAFT ANALYSIS IN Y DIRECTION SIDE CORE AXIS
DRAFT ANALYSIS IN X DIRECTION SIDE CORE AXIS
DRAFT ANALYSIS OF MAP POCKET UPPER PORTION
DRAFT ANALYSIS OF MAP POCKET LOWER PORTION
THE PORTION HIGHLITED IN RED COLOR IS HAVING 0 DEGREE DRAFT WHICH NEEDS TO BE CORRECTED BY CLASS A SURFACE DESIGNER WITH APPROVEL OF HIGHER MANAGEMENT OF THE INDUSTRY.
CLASS B SURFACE:-
CLASS B SURFACE IS THE SURFACE ON WHICH ALL THE ENGINEERING FEATURES GETS ATTECHED THIS SURFACE IS ALSO RESPONCIBLE TO PROVIDING SUPPORT AND STABILITY TO CLASS A SURFACE WITHOUT COMPROMISING THE LOOK OF CLASS A SURFACE.
CLASS B SURFACE OF DOOR LOWER SUBSTRATE
CLASS B SURFACE OF ARM REST
CLASS B OF MAP POCKET UPPER PORTION
CLASS B OF MAP POCKET LOWER PORTION
CLASS C SURFACE:-
CLASS C SURFACE IS THE CONNECTING SURFACE BETWEEN CLASS B AND CLASS A SURFACE TO MAKE CLOSED SURFACE
CLASS C SURFACE OF DOOR LOWER SUBSTRATE
CLASS C SURFACE OF ARM REST
CLASS C SURFACE OF MAP POCKET UPPER PORTION
CLASS C SURFACE OF MAP POCKET LOWER PORTION
JOINING CLASS A, B & C SURFACE TOGETHER
AFTER CREATING ALL THE THREE SURFACES FIRST JOIN CLASS A AND C SURFACE USING JOIN COMMAND (USED TRIM COMMAND TO JOIN ALL SURFACE SO THAT NO BOUNDRY GETS OPEN)
THEN JOINED A,C SURFACE WITH B SURFACE USING TRIM COMMAND TO REMOVE ECCESS PARTS OF B AND C SURFACE AND JOIN THEM
DOOR LOWER TRIM CLOSED SURFACE
DOOR ARM REST CLOSED SURFACE
DOOR MAP POCKET UPPER PORTION CLOSED SURFACE
DOOR MAP POCKET LOWER PORTION CLOSED SURFACE
SOLID BODY CREATION FOR ALL THE PARTS
SWITCHED TO PART WORK BENCH FROM GENERATIVE DESIGN WORK BENCH AND AND CREATED SOLID BODY USING CLOSED BODY COMMAND.
DOOR LOWER SUBSTRATE SOLID BODY
ARM REST SOLID BODY
MAP POCKET UPPER PORTION
MAP POCKET LOWER PORTION
CREATING ENGINEERING FEATURES
FLANGE MAKING
CREATED FLANGE AS PER THE GIVEN MASTER SECTION
PURPOSE OF MAKING FLANGE IS TO CREATING EXTRA PORTION WHERE HEAT STAKE OF OTHER PARTS GETS ATTECHED
MAKING HEAT STAKE
HEAT STAKE IS ENGINEERING FEATURE USED TO JOIN TWO DIFFERENT BODY TOGETHER.
ALSO CREATED RIBS TO PROVIDE SUPPORT TO HEAT STAKE
DOG HOUSE MAKING
DOG HOUSE ARE THE SUPPORTING ELEMENT USED TO MOUNT PLASTIC TRIMS WITH SHEET METAL PART USING PUSH PINS, SOME TIMES IT IS USED TO CREATE LOCATORS OR HEAT STAKE TO PROVIDE ADDITIONAL STRENGTH TO THEM.
RIB
RIBS ARE THE ENGINEERING FEATURES USED TO PROVIDE STRENGTH TO MAIN BODY
FINAL DOOR TRIM ASSEMBLY
DRAFT ANALYSIS FOR FINAL PRODUCT
DOOR LOWER SUBSTRATE
ARM REST
MAP POCKET UPPER PORTION
MAP POCKET LOWER PORTION
PARTING LINE FOR FINAL PRODUCT
PARTING LINE IS THE LINE SEPERATES THE CORE AND CAVITY OF THE MOULD
DOOR LOWER SUBSTRATE
ARM REST
MAP POCKET UPPER PORTION
MAP POCKET LOWER PORTION
