Week 12- Final project

AIM: To develop the door trim (interior) panel with the given class A input and master sections using CATIA V5.

DOOR TRIM: The panel covers the inside of door trim where various electrical components of the car are connected.We design the plastic side of door trim panel which is attached th the sheet metal through various b side features.

The object is thickened to get the component which is suitable for manufacturing

CLASS A SURFFACE:

The class A surface is the one where the customer view the component ,it should be attractive,aesthetic and it doesn't contains any engineering operations.This A surface are created by the styling team.

MULTI-VIEW OF THE GIVEN CLASS A SURFACE:

CLASS B SURFACE:

The class b surface is created with reference to A surface which is offseted to distance which is measured in master section.The class B surface is the one where all the engineering features will be created.The b surface of the component are created which is showed on image below.

The image shows the lower substrate of door trim

The above image shows door arm rest which is offseted from the given input,the offset operations may create sub element missing error we need to recreate the missing elements through various operations which should be toolable.

The above image shows one of the map pocket

The above image shows another map pocket where the bottle holder will be present.

C SURFACE :

The c surface is created for a component by creating the boundary and sweep the curve with reference to the surface make sure to make a draft angle,mostly the c surface is perpendicular to the A surface .The c surface should be attached to the A surface which should be trimmed with B surface.

This image shows the c surface of lower substrate.

This image shows the C surface of door trim. The c surface is different from other since it can not be taken as single structure we have to split the boundary of door trim to two parts and sweep the surface.

It shows the image of c surface of map pocket.

DRAFT ANALYSIS:

The draft analysis must be done on the component in order to check the draft angle provided for the coomponent. The advisable value for the draft angle is 0.5 - 3 deg which is the nominal value for the draft iin plastic component,the draft analysis done on the component on the axis where the component is moulded.The drafts are vvery essential for the component manufacturing,the drafts are provided on all the engineering features.For textured faces the draft angle is 7 deg.

Tooling axis and side core axis are used for the draft analysis.

The following image depict the draft analysis of door arm rest on the side core axis to clear the cavity.

CLOSED BODY(creation of solid):

The final plastic component is created from the closed body and make the component as solid which is suitable for manufacturing. make sure the surface is completly closed before using the close sueface operation. Only the closed body is suitable for manufacturing.

MULTI VIEW OF CLOSED BODY:

B-SIDE FEATURES:

HEAT STAKES:

The heat stakes are the structures which are used for plastic welding.This is of permanant joint by using controlled melting.Heated thermal tip is used for this process,which is easy method of joining.The draft angle used for the heat stakes is 0.5 deg.this image shows the heat stake with reference to the master section.

RIBS:

The ribs are supporting structures which gives strength to the thin surface.It should be connected to other structural features.The draft angle for the rib is 0.5 deg,advisable fillet radius is 0.25-1 mm.The design guideline for the rib creation is shown below.

The below image shows the rib structure.

DOG HOUSE:

The dog house is the structure to have the screw boss/push clips on it.The dog house is used for the screw boss where we needed increased height.The c surface of the dog house should be 40% of wall thickness.The structure is attached to the component.The dog house is used to avoid sink marks.

The below image shows the dog house

PUSH PIN:

The push pins are used for fastening or joining two objects which is made up of plastic.The below image shows the push pin.The push pins are created by extracting the given part body and make them a solid body.

REAL- TIME DOOR TRIM: