Week 12- Final project
Door trim lower panel-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 software
Procedure followed for the creation of the components:
1.Analyse the input surface provided
2.Class A surface as input surface
3.Tooling axis creation
4.Draft analysis of class A surface
5.Class B surface creation
6.Class C surface creation
7.Solid surface body generation
8.Draft analysis of the solid body
9.creating the B side features
10.Draft analysis of the solid body along with the B side features .
Class A surface:
Class A surface is an asthetic 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 thet means it generally accommodate the thickness of the whole plastic component
The input provided for the design is
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
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
So, its perfectly clearing the draft of 3 degrees with the generated tooling axis
Solid body creation:
Go to the part workbench and use the close surface feature to form the solid body out from the close surface body and perform the draft analysis
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 ther B side but some of the surfaces thet leads to a lower draft opr the negative draft mainly these issues rise when there is an issue with the class A surfcae .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 areport regarding issue 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
From tye results we obtain from the draft analysis of the solid body we could come to conclude that the quality of the surface provided in the input surface is not good that is the surface does not have any draft in the class A itself so we need to get a report to alter the changes in the class A surface from the team .
Bottle holder design:
The input surface provide for the bottle holder is
Tooling axis creation:
In case of the bottle holder the we extract the surface in the Y direction orientation and use the point - direction to generte the tooling axis of the bottle holder
Draft analysis of the class A surface:
Perform the draft analysis of the class A surface with a draft angle of 3 degrees the result obtained is
In the draft analysis some of the patches are red ( the draft is 0 or below zero ) and some in blur region shows that the draft is ( greater than 0 and less than 3). So we need to report to the class a team as te draft on the given input surface is not appropriate and need to get an update a class A surface So in this we need to continue forward with this draft analysis results for the further creation
Solid surface creation:
Once the closed surfae is created then go to the part workbench and use the solid surface feature to generate the solid body out of it 
Draft analysis of the solid surfcae body:
perform then draft analysis of the solid body with a draft angle of 3 degrees
The obtained results are the
The entire surfaces of the solid body cannot be able to clear the draft analysis in then solid body because of the errors that spotted on the class A surface draft analysis so we need to make a report including the errors that spotted on the solid body too and submit to the respective team to alter then changes in the input surface to obtain a proper output This negative draft is mainly due to the inclined curvature edges and the improper continution of the edges along the surfaces these are the changes that need to be updated and rectified by the class A surface input team.
Lower substract:
The input surface provide for the lower substract is
Tooling axis creation:
In case of the lower substract the we extract the surface in the Y direction orientation and use the point - direction to generte the tooling axis of the lower substract
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
Solid surface body formation:
Now go to the part work bench and use the solid surface feature to create the solid surface body
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
Almost all the surfaces are clearing the draft analysis in the B side direction.Some of the surfaces are generating the negative draft or the draft angle less then the 3 degree
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.
Arm rest design:
The input surface provide for the Arm rest is
To check whether the surface has any oen boundaries use the boundary feature then we can identify that there is an open patch or the surface which we need to worked on it so improved class A is
Tooling axis creation:
In case of the arm rest the we extract the surface and create a line normal to surface to generte the tooling axis of the arm rest
side core axis creation:
In case of the arm rest the we extract the surface in the Y direction orientation and use the point - direction to generte the side core of arm rest
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 surfcaes of the clsss A is cleasring the draft analysis or not
General draft angle provided on the plastic engineerng componenet is 3 degrees
Here some of the surfcaes of the class a surfcae cannot be able to claer 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
Solid surface body formation:
Now go to the part work bench and use the solid surface feature to create the solid surface body
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
Once all the solid bodies of the components are generated we need to move onto the B sifde attachment features
The B side attachment features may include the
1.Dog house
2.Ribs
3.Screw bosses
4.Flanges
5.Heat stakes.
B side attachment features:
B side attachments on the Lower substract:
Based on the master sections provided for the for the input surface of the lower substrate it indicates theat the heat stakes are positioned on the surface
Heat stakes and Ribs:
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-molded 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 elrement should be isolated from the master section
Draft analysis of Heat stakes and ribs:
Locators:
- Locators are used to locating the position of the mating part while assembling.
- The design rule for the locator is mostly the same as the rib but the height of the locator should be more than the heat stakes at a min of 5mm.
- The locator also constrains the movement of the mating part.
- The gap between Flange and the locator should range between 0.5mm and 1 mm.
- There are two types of locators.
1. 2-Way Locator.
2. 4-Way Locator.
The design rules follows the same as in case of ribs followed by some changes the sketch is
Draft analysis of Locators:
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.
Draft analysis of Doghouse:
Pushpin:
B side attachments on the Door arm rest:
Flanges are the joining features that help to assemble different components. The mastersection was used to make flanges. After creating one flange point to point translation is used to translate the flanges. We need to provide a draft of 0.5 degrees for the flanges . The gap between flanges should be 50-100 mm. Boolean operations were used to add attachment features into closed body
Draft analysis of Flanges:
B side attachments on the Bottle holder:
In case of the bottle holder there didnot provide any master section for the B side attachment so we need to follow the design parametes and create the flanges with respect to the attachmnets on the lower substract and the map pocket
Draft analysis of Partbody:
B side attachments on the map pocket :
In case of the map pocket we use tye master section references for creating the flanges for generating the proper assembly between the compoemts
Here we consider two master sections one with respect to the lower substract and other with the bottle holder
Draft analysis of Partbody:
Assembling the push pins to the dog houses
For this create an axis on the push clops and create the axis on the top cut out on the dog house and apply the coincidence constraint
And apply the coincidence constraint for the surface for proper sitting of the pushclip on the top of the dog house
B side attachments on the Door trim lower panel:
