Week 12- Final project

REPORT:

Aim:

• To develop a Door Trim Panel from the given master section by considering the inputs as like in OEM and Tier-1 companies.
• To find a attachment strategy for the door panel complete work.
• To use Push pin with Dog house for Lower substrate – Door panel attachment.
• To use heat stakes for part to part attachment.

Objectives:

• To create Iso-constrained sketches,individual tooling axis and perform draft analysis.
• To create thickened part using master section for reference.
• To create the mounting features as per design guidelines in the industry and with master sections.

Software Used: CATIA V5

Commands Used:

• Point,line,plane,Positioned sketch,constraint,extract,thick surface,extrude,offset,split,trim,edge fillet,extrapolate,axis,measure item,measure between,join,intersection,circle,boundary,sweep,spline,multiple extract,multi-section surface,curve smooth,geometrical set,body,publications,close surface,pad,translate,draft,draft analysis,existing component,contact constraint,offset constraint,manipulation,graph tree reordering,normal view,isometric view,create multi-view,fit all in,customize view parameters,part.

Procedure:

• Given class-A surface & master sections.

Tooling Axis:

• Tooling axis is created for all the parts individually.

Draft Analysis on class-A surface:

Map Pocket:

• Draft analysis is performed on the class-A surface of map pocket with 3 degree draft angle

Bottle Holder:

• Draft analysis is performed on the class-A surface of bottle holder with 3 degree draft angle.

Lower Substrate:

• Draft analysis is performed on the class-A surface of lower substrate with 3 degree draft angle.

Arm Rest:

• Draft analysis is performed on the class-A surface of arm rest with 3 degree draft angle

Map Pocket:

• The class-A surface of map pocket is given and the tooling axis is created for the map pocket.

Class-B surface:

• The given class-a surface is directly offsetted by 2.5mm and extrapolated the offset surface to create class-B surface.

Class-C Surface:

• A boundary is created using class-A surface.
• And then using the boundary a sweep is created with profile type as line and subtype as with reference surface with the draft direction in 87°.

Final Plastic Component:

• Unhide the Class-A&C join surface and the class-B surface.

• Now create intersection between class-A&C join and the class-B surface.

• split both the surfaces with intersection and using join command join the splits to form final plastic component.

Solid Component:

• Using close surface,a solid model of the map pocket is created from the plastic component.

Bottle Holder:

• The class-A surface of bottle holder is given and the tooling axis is created for the bottle holder.

• The class-A surface has a missing patch as shown in the figure.

• Then the missing patch is improved by using boundary,multi section surface and join command.

Class-B surface:

• The given class-a surface is directly offsetted by 2.5mm and extrapolated the offset surface to create class-B surface.

Class-C surface:

• A boundary is created using class-A surface.
• And then using the boundary a sweep is created with profile type as line and subtype as with reference surface with the draft direction in 87°.

Final Plastic Component:

• Unhide the Class-A&C join surface and the class-B surface.

• Now trim the unwanted surfaces to create plastic component.

Solid Component:

• Using close surface,a solid model of the bottle holder is created from the plastic component.

Lower Substrate:

• The class-A surface of bottle holder is given and the tooling axis is created for thelower substrate.

Class-B surface:

• The given class-a surface is directly offsetted by 2.5mm and extrapolated the offset surface to create class-B surface.

Class-C surface:

• A boundary is created using class-A surface.
• And then using the boundary a sweep is created with profile type as line and subtype as with reference surface with the draft direction in 87°.

Final Plastic Component:

• Unhide the Class-A&C join surface and the class-B surface.

• Now trim the unwanted surfaces to create plastic component.

Solid Component:

• Using close surface,a solid model of the lower substrate is created from the plastic component.

Arm Rest:

• The class-A surface of bottle holder is given and the tooling axis is created for the arm rest.

• The class-A surface has a missing patch as shown in the figure.
• Then the missing patch is improved by using multiple extract,extrapolate,trim,spline,split command.

Class-B surface:

• The given class-a surface is directly offsetted by 2.5mm and extrapolated the offset surface to create class-B surface.

Class-C surface:

• A boundary is created using class-A surface.
• And then using the boundary a sweep is created with profile type as line and subtype as with reference surface with the draft direction in 90°.

Final Plastic Component:

• Unhide the Class-A&C join surface and the class-B surface.

• Now trim the unwanted surfaces to create plastic component.

Solid Component:

• Using close surface,a solid model of the arm rest is created from the plastic component.

Engineering Features:

Flanges:

• The sketchs for flange is extracted from the given master section of door panel.

• The sketches are extracted,sweeped and extrapolated to create surfaces.

• The surface is now thickened and the edges are filleted.
• Based on the attachement, the flange is created for heat stake and locator.

Heat Stake:

• The sketch of the heat stake is created and paded according to the 25mm in y-axis.

• The heat stake is provided a draft of 0.5° and filleted with a value of 0.25mm

4-Way Locator:

• The sketch of the 4-Way locator of measurement 14mmx14mm is created.
• The sketch is paded using pad command.
• And Provided a draft of value 0.5°,chamfered the edges a length of 3mm and given a fillet value of 0.3mm.

Doghouse:

• The sketch of the doghouse of measurement 30mmx30mm is created.

• Extrude the given sketch using extrude command.
• Then extracted the line,extrude the extracted line and offset the line to the required distance.

• Now trim the unwanted surfaces to form the doghouse surface.

• Now thicken the surface thicken command.
• Create the core part and split it.
• Draft the surfaces of the doghouse(Inner:0.5° & Outer:1.5°).

• This is the sketch of the surface cut on the top of the doghouse.

• Extrude the sketch of the surface cut to split it from the top surface of the doghouse.

• The sketch of the ribs is created based on the push pin.
• Then extruded the sketch and thickened the extruded surface.
• Now draft the ribs surfaces of angle 0.5°.

• Now perform union trim on the to form a doghouse with ribs.

Draft Analysis:

Map Pocket:

• Draft Analysis is performed on plastic component with main tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

• The minimum draft angle is at this surface is 84.668°.

• The minimum draft angle is at this surface is -0.858°.

• Draft Analysis is performed on solid component with main tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

• The minimum draft angle is at this surface is 0°.

• The minimum draft angle is at this surface is 0.272°.

Bottle Holder:

• Draft Analysis is performed on plastic component with main tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

• The minimum draft angle is at this surface is -84.768°.

• The minimum draft angle is at this surface is 0°.

• The minimum draft angle is at this surface is 2.059°.

• Draft Analysis is performed on solid component with main tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

• The minimum draft angle is at this surface is -57.719°.

• The minimum draft angle is at this surface is 0°.

• The minimum draft angle is at this surface is 0°.

Lower Substrate:

• Draft Analysis is performed on plastic component with main tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

• Draft Analysis is performed on solid component with main tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

• The minimum draft angle is at this surface is -82.06°.

• The minimum draft angle is at this surface is 0.22°.

• Draft Analysis is performed on solid component with main tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

• Draft Analysis is performed on solid component with side core tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

Arm Rest:

• Draft Analysis is performed on plastic component with side core tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

• The minimum draft angle is at this surface is -22.717°.

• The minimum draft angle is at this surface is -23.823°.

• The minimum draft angle is at this surface is 1.85°.

• Draft Analysis is performed on solid component with side core tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

• The minimum draft angle is at this surface is 0°.

• The minimum draft angle is at this surface is -20.224°.

• Draft Analysis is performed on doghouse with side core tooling Axis.
• Draft is angle is 0.5°.
• The draft is positive for class-A surface because the minimum draft angle is 0.5°.

Final Assembly:

Graph Tree:

Conclusion:

• Tooling Axis are created individually.
• Plastic component is created with mastersection.
• Door Panel thickened part is created with mastersection.
• Solid model of Door Panel is created and Draft Analysis is performed on the Class-A surface,Plastic component,solid component,Doghouse.
• Mounting features are created as per design guide lines.
• Push pin is attached with dog house.