Week 12- Final project
REPORT:
FINAL PROJECT-DOOR TRIM PANEL DEVELOPMENT
For the final assessment, door trim panel is to be developed with given surfaces and master sections. Using this as reference, other engineering features and attachment strategies are to be developed.
Before going to dive into design part, we have to reorder the tree a structured format so as to ensure easy identification of parts. This is shown below:
There are 4 parts here.
1. Lower substrate
2. Upper substrate
3. Map pocket
4. Arm rest
They are to be developed as seperate parts and rejoined to obtained the final product. Each part development follows a structured flow, or algorithm. First we need to take Class A surface from the given surfaces for each part. Then using this class B, Class C, Closed surface, Solid model..etc. are to be developed. Draft analysis of parts should also be done.
1. LOWER SUBSTRATE
- CLASS A SURFACE
The class A surface for lower substarte is obtained from the given CAD.file. The surface is checked for any irregularities or flows. It was found good for further proceedings.
- DRAFT ANALYSIS OF CLASS A
For draft analysis, first tooling axis is to be made. An aribitary point is taken on the surface, and tooling axis is made normal to the surface in the global 'y' direction. This method is followed because as per the geometery of lower substrate, the surface should clear draft analysis in normal direction. The draft analysis result is as follows:
The surface in light brown colour is class A and that in yellow is class B
For class C surface creation, the boundary of class A is extracted. With refernce to class A, the boundary is swept at 90 degrees to class A.
Figure shows class A in light brown color and class C in blue colour.
- CLOSED SURFACE AND SOLID BODY CREATION
For obtaining a closed surface, the first class A and C surfaces are joined together. Now this is trimmed with class B surface to obtain the final closed surface. In the part workbench, using closed surface tool, solid body of the lower substrate is created.
The Solid body is shown above:
- DRAFT ANALYSIS OF SOLID BODY
Draft analysis of solid body is done with respect to tooling axis. The result obtained are statisfactory.
Now we have to design the engineering features on to this lower substrate.
- ENGINEERING FEATURES CREATION
From the refernce and problem description. Lower substrate consists of heat stakes/locators and dog house for pushpin. Heat stakes are made using master section as reference. frome the master section, the dimension of the circles for the heat stakes was found to be 4.5mm and 7.5 mm. Theya re padded an dribs are added to avoid sink marks. HEat stakes are modeled as follows:
A total of 13 heat stakes were provided in lower substrate.
Dog House design is done purely based on engineering principles,with a hieght of 30mm. The cut in the lower protion is also molded as per principles. Adequate drafts and fillets were provided for the dog house. The purpose of this is to hold the push pin clip. The psuh clip model was given. Thus a dog house-push pin clip assembly was created as follows:
3 dog house push slip assembly and heat stakes were added to lower substrate to obatin the final output as follows:
2.UPPER SUBTRATE
The constuction of upper substare is similar to that of lower substrate.
- CLASS A SURFACE
The class A surface for lower substare is obtained from the given CAD file. The surface is checked for any irregularities or flaws. It was found good for further proceedings.
- DRAFT ANALYSIS OF CLASS A
For Draft analysis, first the tooling axis is to be made. An arbitary point is taken on the surface, and tooling axis is made normal to the surface in the glopbal 'Y' direction. The draft analysis result is as follows:
The result obtained are good and we can proceed with further design of class B and C surfaces.
- CLASS BA ND C SURFACE CREATION
Class B and C surfaces are created using the class A surface only. Classs A surface is offseted to 2.5mm to get class B surface. There will be some corrections to be done in the class B surface after offsetting from the class A. These can be rectified by using multisection tool. The class B surface(cyient) is shown below
Class C surface joins class A nd B and forms a closed usrface body. The boundary of class A is extracted and is swept at right angle to the A surface, to obtain class C. CLass C surface is shown in yellow colour below.
- CLOSED SURFACE,SOLID BODY CREATION AND DRAFT ANALYSIS OF SOLID BODY
Once the creation of B and C surfaces are over, they have to be joinedto form th e closed surface body. For that, first A and C surfaces are joined and later this assembly is trimmed to form the closed surface. Using the closed surface tool in the part workbench, a solid body created out of it. This will serve as our main body for upper substare. The solid body is shown below.
After creating the main body, draft analysis is to bve done in order tro ensure smooth ejection of the part from core. The analysis is carried out using the tooling axis craeted for draft analysis of class A surface. The results obtained are satisfactory and is given below:
- ENGINEERING FEATURE CREATION
Flanges are required for upper substrate , in order to get assembled with lower substrate, as per master section given. The flanges are created using master sections as references. Typical flange for upper substrate is as follows:
A total of 4 flanges are created and they are trimmed with main body to obtain final upper substrate body as follows:
3. MAP POCKET
- CLASS A SURFACE & DRAFT ANALYSIS
Fom the inputr CAD fil, the Class A surface for map pocket is atken and pasted on the new part for construction. The surfaec has no flaws. so we can proceed with further designing. Class A surface for Map pocket is shown below:
Now, bedore moving to further steps, draft analysis needs to be carried out. For that tooling axis made in the normal direction with respect to that face on class A surface (in global 'y' axis). Every point except the side walss cleared drsft analysis with 3 degree draft angle. For side walls, it is 0 degree, which is to be addressed by class A designer.
- CLASS B AND C SURFACE CREATION
Class B and C surfaces are created using the class A surface only. CLass A is offseted to 2.5mm for obtained class B, Where as boundary of Class A is swept at right at right angle to obtain class C surface.
The figure shows Class A in pink colour and class B in cyient Colour.
Figure shows the class A in pink colour and class C in yellow colour.
- CLOSED SURFACE AND SOLID BODY CREATION
Class A and Class C surfaces are trimmed with class B surface to obtain the closed surface body as depicted in the figure below
Now a soild body is to be made out from this closed surface body. This can be done by using closed surface tool in part workbench. The final main body for map pocket is created.
- DRAFT ANALYSIS OF SOLID BODY
Afte creation of solid body is to be done. On analysis, the problematic area in the draft analysis of class A reoccurs here as well. Except this part, every other point clears draft angle of 3 degree.
- ENGINNERING FEATURES CREATION
For Map Pocket, with refernce to the master ssection, the flanges are reqired for aligning with locators/ heat stakes on lower substrate are made with the refernce from the master sections. Typical flange for map pocket is as follows:
Later these are trimmed with main body to obatin final body for map pocket. Essential fillets are provided to flange:
Thus the final Map pocket is obtained.
4.ARM REST
- CLASS A SURFACE & DRAFT ANALYSIS
The class A of Arm rest required some reworks before moving to further proceedings due to some error with the surface. Some extractions and trims are done and unwanted portions are deleted. The final class A used is as follows:
For the darft analysis, tooling axis was made in the normal direction to the surface. But on draft analysis, the side faces did not clear minimum draft angle requirement. This problem is to be rectified by the class A designer. The figure below shows the result obtained:
- CLASS B AND C SURFACE CREATION
Unlike other geometeries in this project, arm rest class b design is different. The given surface is of a cushoning surface, so we have to offset twice to get the given surface. Offseting this surface to respective lengths obtains our required B1 and B2 surfaces. Multisection, trim, split etc. were used for surface improvemnets. Class C surface is created by sweeping the boundaries of class B1 surface normal to it. The class B1, B2 and C surfaces are made.
- CLOSED SURFACE AND SOLID BODY CREATION
Class B1 and class C surfaces are joined and tyrimmed with class B2 surface to get the final closed surface body. Now, a solid body i sto be made out from this closed body. This can be done by using closed surface tool in part workbench. The final main body for arm rest is as the given in the figure below:
Now engineering features (flange) are to be attached to this body.
NB: Draft analysis for main body not done beacuse, it has flaws in the surface and will not cleart with required draft angle.
- ENGINEERING FEATURE CREATION
From the master section, it is clear that the arm rest consiting flanges which get alaigned with the heat stakes/locators in lower substarte. This is created using given master section. 3 flanges shows a flange for arm rest:
Later, these are assembled into a single body and trimmed with main body to obatin final arm rest body. Adequate fillets are given.
Figure shows final arm rest body.
FINAL BODY-DOOR TRIM PANEL
Isometeric view:
Front view:
RIght side view:
Left side view:
Top view:
