Week 12- Final project

The given Door trim panel has a four majar parts. These are

1. Arm rest
2. Lower substrate
3. Map pocket and
4. Bottle holder.

1. Arm rest :

• First I was check the given class A have any open patch.
• If it have a open patch, then work on to correct the problem.
• The arm rest have a open surface so we resolve the issue.

Tooling axis creation :

• And find which direction is suitable for create a tooling axis.
• In this part I use the bisecting method to create the main tooling axis.
• Some areas are not clearing the draft analysis.
• So I create a side core axis for this part.

Draft analysis for given class A surface :

• Change the view to customize view and change the material then give ok.
• Click the compass and place on the main tooling axis.
• Then click on the class A surface.

• The inside area is not clearing the draft analysis.
• So create the side core axis and place the compass on the side core axis.

Class B surface creation :

• First I check the mastersection to find the thickness of the part.
• Then offset the class A to 2.5mm.
• Some areas are not forming to create a open patch.

• I make a multisection surface to clear one patch.
• And encounter the another path by using extract, extrapolate, split, trim and join commands.

Class C surface creation :

• First create a separate boundary of the class A surface.
• Do the sweep with reference surface for which edge is parallel to the main tooling axis.
• And do the sweep with draft direction for which edge is perpandicular to the main tooling axis.

• Some curvature areas sweep cannot create so use the multi section suface to make the suface.
• And use the trim and join command to make the full Class C surface.

Class A and C join :

• Use the join command to join the Class A and C.

Final trim :

• Then extrapolate the edges of the class B and AC join.
• Make the intersect to trim them.

Closed part creation :

• And insert a new body and define that body as a working object.
• Then jump into the part design.
• Select the closed surface and select the trim.
• We get a closed part.

Draft analysis for closed part :

• Some areas not clearing the draft analysis.

• Draft analysis with side core axis :

2. Lower substrate :

• First check the given class A have any open surface.
• In the lower substrate doesn't have open surface.

Tooling axis creation :

• Find which direction is suitable for creation tooling axis.
• In this part I simply give the line and direction to create the main tooling axis.
• Also some of the B side features will create on the part.
• So I create the side core axis for the B side features.

Draft analysis for Class A surface :

• First change the view to the customize and click the material then give ok.
• Select the feature draft analysis.
• Then click the compass and place it on the main tooling axis.
• And select the class A surface.

B surface creation :

• In the lower substrate part I simply offset the class A surface at 2.5mm.
• I doesn't create any problem.

C surface creation :

• First I create a separate boundaries for sweeps.
• Use extrapolate to make them intersect.
• Then do the trim to make a single surface.

Class A and C join :

• To join the Class A and C surface using the join command.

Final trim :

• Extrapolate the Class B and Class A C join to make them intersect.
• And do the final trim to get the closed surface.

Closed part creation :

• Insert a new body and define as a working object.
• Then jump into the part design.
• Click the closed surface command select the trim and click ok.
• We get a closed part.

Draft analysis for closed part :

• First change the customize view to select the material then give ok.
• Select the feature draft analysis command.
• Click the compass and place it on the main toolling axis.
• And select the closed part.

• Below some areas not clearing the draft analysis.

3. Map pocket :

• Always check the given class A have any open surface.
• In this map pocket doesn't have any open surface.

Tooling axis creation :

• Find which direction is suitable for creating the tooling axis.
• In this part I simply create a line with the direction.

Draft analysis for Class A surface :

• First change the view to customize view and tick the material and give ok.
• Select the compass and place it on the main tooling axis.
• Then click on the class A surface.

B surface creation :

• Offset the class A at 2.5mm.
• It doesn't create one fillet surface.
• I create that surface by use the multisection surface.

C surface creation :

• Create a separate boundaries of class A to create a sweep.
• Use sweep with draft direction for which edge is perpandicular to the tooling axis.
• And use sweep with referance surface for which edge is parallel to the tooling axis.

• Some areas not create, so use the multisection surface to create the surface.
• Then use the join command to join them.
• Use extrapolate command to intersect the surfaces to make the trim.

Class A and C join :

• Use the join command to join the class A and C surfaces.

Final trim :

• Extrapolate the edges of Class A C join and Class B surface.
• Make them intersect then trim them to get a closed surface.

Closed part creation :

• Insert a new body and define as a working object.
• Then jump into the part design.
• Select the closed surface and select the trim to get a closed part.

Draft analysis for closed part :

• First change the view to customize view and tick the material then give ok.
• Click the feature draft analysis.
• Select the compass and place it on the main tooling axis.
• And click on the closed part surface.

• Some surface doesn't clear the draft analysis.

4. Bottle holder :

• First check the Class A surface have any open surface.
• In that bottle holder doesn't have any open surface.

Tooling axis creation :

• Find which direction is suitable for creating a tooling axis.
• In this part I simply create a line with direction to make a tooling axis.

Draft analysis for class A :

• Change the view to customize view and click the material and give ok.
• Select the feature draft analysis.
• And click the compass and drag it to place on the tooling axis.
• Then click on the class A surface.

• Below some areas not clearing the draft analysis.

B surface creation :

• In this part I simply offset the class A surface at 2.5mm.

C surface creation :

• Do the sweep with referance surface to create a sweep.

Class A and c join :

• Use join command to join the class C and A surfaces.

Final trim :

• Extrapolate the class A C join and class B surface.
• Make them intersect with each other to make a trim to get a closed surface.

Closed part creation :

• Insert a new body to define as a working object.
• And jump into the part design.
• Select the closed surface and click the trim to create the closed part.

Draft analysis for closed part :

• First change the view to customize view and click material.
• And select the compass and drag to place on the tooling axis.
• Then click on the closed part surface.

• Below some areas are not clearing the draft analysis.

Flange creation in Arm rest :

• First multiple extract the class C surface edge.
• Create a plane on that required area by using three point of master section.
• Also create a point on that center of the plane.
• Create a sketch with use the master section curves as a referance 3d object.
• Use the sweep explicit with referance surface.
• Give profile is a sketch and guide curve as a multiple extract edge.
• And create another sketch for top surface.
• Then extrude the sketch.
• And make the trim.

• Sketches for flange creation :

Thicken surface to create the Flange :

• Insert a new body and define that as a working object.
• Jump into the part design and select the thicken surface.
• And select the trim to give a 2.5mm to the upper direction to thicken the surface.
• Also offset the surfaces on the thicken part to split the flange for required length.
• Then use the split command to split the part.

• And draft the flange faces with side core axis at 0.5deg.
• Finally give a fillet to the edges.

Flange hole creation :

• Create a sketch for the flange hole.

• Insert a body and define a working object.
• Use the pad command to pad the sketch.
• Also give a draft to the outer face at o.5deg.
• Then use the paste special result with link to create a duplicate of the hole pad.
• And translate to the another flange.

Final flange creation :

• Insert a new body then assemble all the flanges to that body.
• And remove the hole pad to that assembly body.

Union trim to the closed part :

• Use the union trim of the flange assembly to the closed part.

Flange creation in map pocket :

• First multiple extract the class C surface edge.
• Create a plane on that required area by using three point of master section.
• Also create a point on that center of the plane.
• Create a sketch with use the master section curves as a referance 3d object for flange 2.
• Use the sweep explicit with referance surface.
• Give profile is a sketch and guide curve as a multiple extract edge.
• And create another sketch for the flange 2 and bottom flange.
• I create the first flange by closed surface. So I create the sketch for that method.

Sketches for creating the Flanges :

Thicken the surface to make a flange :

• Insert a separate body for the separate flange.
• Use the closed surface for the first flange and use the thicken surface for the other two flanges.
• Then offset the vertical surfaces for split the flange for the required length.
• And use the split command to split the flanges.

• And give the draft for the flange faces with 0.5deg.
• Finally fillet the edges for suitable.

Flange hole creation :

• Create a sketch for the flange hole.

• Insert a new body and define as a working object.
• Use the pad command to pad the sketch for required height.
• Then give the draft of 0.5deg for the pad.
• And use the paste special result with link to duplicate the pad.
• Use the translate command to move wherever we want.

• Insert a new body to assemble the flanges to that body.
• Use remove command to remove the hole pad in the flanges to create flange holes.
• Finally union trim the flange assembly to the closed part to make a complete map pocket part.

Flange creation in bottle holder :

• First create a new geometricalset and multiple extract the class C surface edge.
• Then create a separate sketches for the separate flange.
• Use the sweep profile explicit sweep with referance surface.
• Give a profile as a one sketch and the guide curve as a another harizontal sketch to create a sweep.
• Then create a line in a sketch perpandicular to the C surface edge.
• And extrude that to create a surface for split the thicken surface.

Thicken surface of flange:

• Insert the new body for separate flanges to define as a working object.
• And jump into the part design.
• Select the thicken surface and select the sketch for the one flange then select the trim for the another flange.

• Then use the offset surface to split the side limits of the flange.
• And give a 0.5deg draft for the flange faces.

• And give the fillets over the edges of flange.

Flange hole creation :

• Create a sketch for a flange hole.

• Insert a new body and pad the sketch for the required hight.
• Then give a draft for the outer surface at 0.5deg.
• And use the paste special result with link to make a duplicate of the pad.
• Translate the pads wherever we want.

Union trim to the closed part :

• Insert a another body and assemble the flanges in it.
• And remove the flange hole pad to the flange assembly.
• Finally union trim the flange assembly to the closed part to get the final bottle holder part.

Heatstakes creation in Lower substrate :

• First I create a point by mid point of the flange hole master section.
• And create a plane over the point.
• Then I create a heatstake circular portion.
• I measure the heatstake diameter in the master section.
• And create the sketch for the heatstake circle.

• Insert a new body and define as a working object.
• Create a pad using sketch for required hight.
• And draft the inside and outside faces at 0.5deg.
• Then give the fillet to the edge.

• And create a sketch for heatstake rib.

• Insert a body and create a pad by nutral fiber with required hight.
• Then draft the rib faces with tooling axis at 0.5deg.

• Insert a new body and add the bush and union trim to the bush.
• Then use the paste special result with link to duplicate the heatstake.
• And translate the heatstakes for required areas.
• Insert a another body and add the all heatstake to that heatstake assembly.
• Then union trim to the closed part.

Draft analysis for heatstake assembly :

• Change the view to customize view and select material then give ok.
• Click the compass then drag it to place on the tooling axis.

4 way Locator creation in lower substrate :

• Extract the surface where the locator will fix.
• Then create a point on a surface.
• And create a plane on the point.
• Create a sketch for 4 way locator with respect to the point and the plane.

• Insert a new body and define as a working object.
• Then jump into the part design.
• Pad the sketch for required hight.

• And give the draft for locator at 0.5deg.
• Then give the entry chamfer 3mm.
• Give the fillet to the edges.
• And use the paste special result with link to duplicate the locator.
• Then use translate to move forther we want.
• Insert a body to assemble the locator.
• Finally union trim the locator assembly to the final part to get the final component.

Draft analysis for the Locator :

• Change the view to customize view and enable material and click ok.
  
• Click the compass and place it on the tooling axis.

Doghouse wall creation in lower substrate :

• First extract the surface wherever the doghouse want.
• Create the point on the surface.
• And create a plane on the point.
• Then create a sketch for the doghouse.

• Insert a body and define that as a working object.
• Jump into the part design then click the pad to select the sketch give required hight.
• Give the draft for four faces with tooling axis at 1.5 deg.
• Then use the shell command to select front and bottom face and give 2.5mm to make a proper doghouse wall.

• Also draft the inner face of doghouse with side core axis at 0.5deg.
• And create a doghouse bottom clearance.
• Multiple extract the doghouse inner suface and offset that at 1mm.
• And extract and offset the doghouse bottom face at required hight.
• Then trim them to get the suface.
• Use that surface to split the doghouse.
• Also draft the cutted area at 0.5 deg.
• Then fillet the edges.

Doghouse top pocket creation :

• Create a sketch for the doghouse top pocket.

• Insert a body and pad the sketch for required hight.
• And give a draft to the side faces at 1.5deg.

Doghouse rib creation :

• Create a plane on the point.
• And create the sketch for the rib.

• Insert a body and pad the sketch.
• And draft the rib faces with side core axis with 0.5deg.

• Then insert a new body and define it as a working object.
• Add the doghouse wall to it.
• And use remove to cut the top pocket.
• Use union trim to trim the rib.
• Finally fillet the edges.
• Then use paste special result with link to duplicate the doghouse.
• And translate the doghouse wherever we want.
• Finally union trim the doghouse to the final part to get a final component.

Draft analysis for doghouse with main tooling axis :

Draft analysis for doghouse with side core axis :

Door trim panel product constrains to fix the pushpins :

Draft analysis for Arm rest part :

Draft analysis for Lower substrate part :

Draft analysis for Map pocket part :

Draft analysis for Bottle holder :

Front view, Top view, Side view and Isometric view of Door panel :

Conclusion :

I learn a lot of things while duing the final project. At last all the class A, class B, class C and engineering features are created as per the rule. And I use the publication for finding the things. All the area even wall thickness maintained.