Week 12- 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 

     

Arm rest design

 

In the front of the car, a central armrest, which commonly folds away based on user preference, will also often include a storage compartment and sometimes even cup holders. Some also provide the location for controls for non-essential functions of the vehicle, such as climate control or window motors.

For the Arm rest design the input class a surface provided is 

   

Tooling axis creation:

 

In case of the arm rest we generally deploy the bisection methiod for creating the tooling axis , that is first we need to create a plane and form an intersection of the surface and generate the two lines from the intersection and there by creating a line by using the bisection method

 

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

   

 Generating of the class B surface

 

For the class B surface generation refer to the master section provided to measure the thickness of the plastic component then offset the class A surface to an extend of 2.5 mm thickness beneath the class A surface

   

Generating the class C surface:

 

For the class C surface generation we use the class A surface  as an reference and follow the draft with respect to the reference surface and the main tooling axis

   

Generating the final close surface:

 

After creating the class B and the class C surfaces join the class A and the class C surfaces and trim the resultant with the class B surface then the resultant surface is the final closed surfaces

Then make the B surface trim with the class A & C join

It is the close surface of the plastic componenet with a thickness of 2.5mm

Then create a new body and use the solid body feature to create the solid surface body out of it

   

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

  

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

Design:

 

In case of te door arm rest we need to folow the master section provided for the flange creation

The thickness of the flange is equal to the thickness of the plastic component that is 2.5 mm

The draft provided is 0.5 deg

Apply requierd fillets on all the sharp edges

  

So we need to cfreate the flanges on every position with respect to the heat stakes or the locator which are situated on the lower substract for the assembly

  

Now perform the draft analysis with a draft angle of 0.5 deg

 

Lower substrate:

 

For the lower substrate design the input class a surface provided is 

    

So my class A surface is ready with no open boundaries in the given input surface

Tooling axis creation:

 

Extract the surface from the class A where the surface is entirely visible and easy for the manufacturing by viewing the surface in different orientations

Now create a point at the middle At 0 coordinates and create a line in point and direction method and the create line is our main tooling axis

Creation of class B surface:

 

In case of the lower substract offset the class A surface to a value of 2.5 mm beneath the class A surface then extrapolate the class B surface which would help to make the final trim with the class A and C combined surface

Creation of class C surface :

 

When the surface of the class C is parallel to the tooling axis then make use of the sweep with respect to the draft Direction to an angle of 3 degrees and the surface need to be outside the class A surface when seen from the normal direction with respect to the main tooling axis. And if the class C surface which need to create is perpendicular to the tooling axis then make the sweep with the reference surface With 90 degrees or with 87 degrees

Final surface formation:

 

Now join the class A surface with the class C surface and trim the class B surface with the join A and C surface

  

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

  

 

B side attachment features for lower substrate :

 

The B side attachment features may include the 

1. Dog house
2. Ribs
3. Screw bosses
4. Flanges
5. Heat stakes
6. locators     

 

Based on the master sections provided for the for the input surface of the lower substrate it indicates theat the heat stakes are positioed on the surface

  

Following the master section wee need to create the heat stakes on the lower substract B side 

Heat stakes :

 

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 

 

Pad the sketch with a height represent in the master section taking reference as the tooling axis direction

Now apply the draft of 0.5 degrees on both inner and outer edges.

     

Another attachment feature we create is 4 way locator as when there is a need of more heat stakes but because of the design rule if the distance is not sufficient enough tio create the another heat stake then we create theb  locators and the height of the locator mush be higher than the heat stakes

 

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.

  

The height should be greater than the heat stake and providev a draft of 0.5  degrees selecting the neutral elament as the sketch plane and the pulling direction is the main tooling axis 

  

3. Dog house creation:

 

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.

Here I has used a 20*20 dog house padded to a height of 40mm 

I Applied the shell of 2.5mm to make a cavity in the dog house 

  

 So generally the thickness of the component at the intersection of the dog house with the lower substract is 2.5 mm but with this thickness there may be possibility of plastic defects include the sink marks at the bottom So, the thickness at the contact is reduced to 1mm to 1.2mm as per the thickness of the plastic product. 

For this we generally provide coring for the dog house at the bottom that means the thickness of the componennt would be 1 mm from ouside walls of then dog house 

The thickness maintained should be 1 mm from the ouside walls of the dog house 

 The height of the coring provided is 3mm  upto 6 mm

Now apply a draft of 0.5 degrees on the inner walls of the dog house taking the pulling direction as the side core tooling axis

 

The cutout sketch is 

 

 SO on the lower substract we need to provide upto 3 dog house maintaining that there might not be any engineeering feature with in a direction of the slider movement upto 90mm (minimum distance )

We use the translate option from point to point translation to copy and paste the dog houses atb arious locations and use the rotate option to change the direction of the opening for the slider 

The draft analyiss is 

And the heat stakes & the locators  on the lower substrat along with the draft analysis of 0.5 deg along the main tooling axis is 

  

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 fore the plane for proper sitting of the pushclip on the top of the dog house

   

 

 Now with the help of these heat stakes and the locators create the flages on the adjacent componemts to form a proper assembly among the components 

 

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

Class B surface creation:.

 

Now step forward to create the class B surface deploy the 2.5mm offset of the class A surface to generate the class B surface beneath the class A surface

  

Class C surface creation:

 

Now create the class C surfcae which is an intermediate surface between the class A and the class B surface generally like a fill between the  two surfaces created with the help of the sweep feature with a draft of 3 degrees

along the tooling axis direction and with a draft of 90 degrees along the reference surfcae sweep

  

Final surface creation:

 

Once all the surfaces are created that is the class B and the class C surfaces then join the class A & class C surfcaes and trim the  join surface with the class B surfaceto form the final closed surface

  

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

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

Take the references from the master section and isolate them so that whenever there may be changes in the master section the sketches cannot create any problem

Thicken the surface to 2.5mm and apply a draft of 0.5 deg and apply the proper fillets

  

Thicken the surface to 2.5mm and apply a draft of 0.5 deg and apply the proper fillets

Now create a hole for the heat stake & locator attachment in the flange

  

Now create the attachment features pof heatr stakes and the locators for making the assembly of the componenr with the bottle holder

  

The draft analysis of the B side featues on the map pocket are

  

 B side features 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

Bottle holder design:

 

The input surface provide for the bottle holder is

Tooling axis creation:

 

In the case of the bottle holder use the flat surface and extract the surface and create a point at the 0 coordinates and use the point - direction to create the tooling axis 

Class B surface creation:

 

Now offset the class B surface to 2.5mm following the master section beneath the class a surface and extrapolate the class b edges to an extent to form the proper ytrim with the class A and C join Choose the correct direction for offsetting the surface

 

 Class c surface creation:

 

Now create the class C surface with the aid of the class a surface and the sweep feature along the draft direction and the reference surface parameters . So provide adraft of 3 degrees along the draft direction making the direction of the draft as the main tooling axis and 90 degrees draft with rreespect to the reference surface

Final surface creation :

 

Once all the surfaces are created that is the class B and the class c surfaces join the class C surface with the classs A surface and trim the joined surface with  the class b surface 

This is the final closed surface with the class B & C surfaces 

  

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

 

 B side features 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

 For creating the flanges to follow the class c surfcae we provide an inetersect and coincide the sketch with it 

  

Now thicken the surface to a value of 2.5 mm and provide theb  draft of 0.5 deg along with the fillets 

and create a hole for the attachment to assemble on the flange 

  

The total flangesc & locator created with respect to the lower substrtract,map pocket and the bottle holder is

The draft analyis results of the B side attachments are

  

 

 

 THE FINAL COMPONENTS WITH  B - SIDE FEATURES :