Week 12- Final project
WEEK 12 - FINAL PROJECT
DEVELOPEMENT OF DOOR TRIM PANEL
CLASS A SURFACE
Checking the connectivity by using the boundary or the intersection feature.
CLASS A SURFACE - ARM REST BEZEL
CLASS A SURFACE - SPEAKER GRILL TRIM
CLASS A SURFACE- DOOR TRIM PANEL
CLASS A SURFACE- MAP POCKET TRIM
CLASS B SURFACE
Created by extracing, untrimming it, extrapolating and offsetting it with a thickness of 2.5 before triming it all together.
CLASS B SURFACE- ARM REST BEZEL
CLASS B SURFACE- SPEAKER GRILL TRIM
CLASS B SURFACE- DOOR TRIM PANEL
CLASS B SURFACE- MAP POCKET TRIM
CLASS C SURFACE
Created by using the sweep method, where with the boundary of the class a surface is used as the guide curve and for the referance surface of class A was used, then both the class A and the sweep were trimmed together in the end.
CLASS C SURFACE- ARM REST BEZEL
CLASS C SURFACE- SPEAKER GRILL TRIM
CLASS C SURFACE- DOOR TRIM PANEL
CLASS C SURFACE- MAP POCKET TRIM
STEPS TAKEN TO ACHIEVE THE ABOVE SURFACES
Step 1
We checked through different positions where the part would be able to draft with the minimum draft angle and created a point and a line then cross verified it with draft analysis and we found it out to be the right axis and renamed the line as the Tooling axis.
Step 2
Here we offset the class A surface by 2.5mm and found a part which didn't get offset completely, so to complete the class b surface we used the sweep,blend and the join commands along with the extrapolate and trim commands.
Step 3
To create the class C surface we at first created the boundary on the class A surface and then used the sweep method where the boundaries and tooling axis where chosen and a draft was given. Then we trimmed the class A & B together to form the Class C surface. Then we were able to get a closed surface.
Step 4
We then took the final trim to the product workbench and used the closed surface to thicken the Class C surface.
FINAL TRIM SURFACE
FINAL TRIM- ARM REST BEZEL
FINAL TRIM- SPEAKER GRILL TRIM
FINAL TRIM- DOOR PANEL TRIM
FINAL TRIM- MAP POCKET TRIM
Step 5
We then created Side Flanges dimensioning it accoring to the master sections, by projecting the lines isolating, iso-constaining it and utilising the pad commands, we also had to create certain holes in the side flanges for the heat stakes to fit into, this was done using the remove operator after pading the hole. These Side Flanges were created on the Arm Rest Bezel, the Door Trim Panel and the Map Pocket Trim. All the Side flanges were union trimmed to their respective closed surfaces.
We then moved on to create the heat stakes on to the Speaker Grill Trim to fix the parts with the side flanges, simple pad and translate commands were utilised. Now that the heat stakes was completed we then created the Dog House for the Speaker Grill Trim as it would act as an attachment to the sheet metal part of the door. At first we created the sketch, extruded it, created a closed surface after padding it then gave it a draft and then created the inner features and union trimmed it all together completing it by creating the hole for the push pin on top and concluded everthing by giving the necessary edge fillets. Later all the Heat Stakes and the Dog House created were union trimmed to the closed surface of the Speaker Grill Trim.
ATTACHMENT FEATURES
SIDE FLANGES
Side Flanges are a a type of a rib used for strength, for guiding or for attachment purpose of one object to another.
SIDE FLANGES- ARM REST BEZEL
SIDE FLANGES- DOOR TRIM PANEL
SIDE FLANGES- MAP POCKET TRIM
HEAT STAKES
Its a process to attach two seperate components by melting the base plastic into a shape that will hold the secondary component. This process helps cut down the extra manufacturing costs as it doesn't require any additional materials such as adhesives or screws to make any attachments.
HEAT STAKES- SPEAKER GRILL TRIM
DOG HOUSE
Dog house is an engineering feature used in plastic design. They are used as support feature and sometimes other engineering features like snaps, locators, screw bosses are mounted on them to increase their strength.They are subjected to draft analysis to prevent breakage of the component during ejection from the mould cavity.
DOG HOUSE- SPEAKER GRILL TRIM
PUSH PIN CLIPS
Its used to secure various parts in automotive industry such as panels, trim pieces etc.
Step 6
We then took the final closed surface then did the draft analysis, we dragged the compass fixed it to the tooling axis and checked for any undercuts and we achieved an all green surface thus completing the challenge.
DRAFT ANALYSIS
DRAFT ANALYSIS- ARM REST BEZEL
DRAFT ANALYSIS- SPEAKER GRILL TRIM
DRAFT ANALYSIS- DOOR PANEL TRIM
DRAFT ANALYSIS- MAP POCKET TRIM
This way we able to complete the Door Trim Developement Final Project sucessfully.