Development of a Door Trim panel

Aim:

To create a CAD model considering the following inputs as like in OEM and tier1 companies

a) Class A surface

b) Nominal thickness: Refer to master sections

c) Attachment strategy :

And to find an attachment strategy for the door panel complete work.

Use Push pin with Dog house for Lower substrate – Door panel attachment

Use heat stakes for part-to-part attachment.

Door Trim Panel

Armrest

Tooling axis:

Extract the surface

Create a middle point of the extracted surface.

Create a new axis system at the middle point.

Create a line normal to the surface at the middle point.

Intersect the surfaces along the XZ axis and ZY axis.

Create two-point lines along the inclined side walls.

Create a bisecting line at the middle point using two-point lines.

Create another bisecting line using the normal line and the bisecting line.

This new bisecting line is the tooling axis.

Side core axis

Extract the side surface

Create a centre point on the extracted surface.

Create a line normal to the surface along the centre point.

That is the side core axis.

Draft analysis of Class A surface

Select the customize view parameter and select the material.

Select the Draft analysis tool

Adjust the draft axis dir to the moulding axis using the compass.

The green colour shows the draft above 3 degrees, the red colour below 0 degrees and the blue colour means o deg.

Draft analysis along the tooling axis:

Draft analysis along the Side core axis:

The solid bodies by making proper class B and class C surfaces

Trim and correct Class A surface

Offset the surface to a 2mm distance below the class A surface.

The yellow colour surace is the Class B surface and the blue is the edited Class A surface.

The B surface requires some trimming and extension.

Create the Class C surface

Join the edited Class A surface and Class C surface

Then trim the joined Class A and C surface with the extended Class B surface to create a closed surface.

Using the closed surface to create the part body.

Draft analysis of Solid body

Select the customize view parameter and select the material.

Select the Draft analysis tool

Adjust the draft axis dir to the moulding axis using the compass.

The green colour shows the draft above 3 degrees, the red colour below 0 degrees and the blue colour means o deg.

Draft analysis along the tooling axis:

Draft analysis along the Side core axis:

Creating Flanges

Top substrate

Tooling axis:

Extrude the middle surface and create a middle point on that surface.

Place an axis at that point.

Intersect the surface to the ZY plan.

Create two two-point lines at the inclined intersections.

Create the tooling axis using a bisecting line using those two point lines.

Draft analysis of Class A surface

Select the customise view parameter and select the material.

Select the Draft analysis tool

Adjust the draft axis dir to the moulding axis using the compass.

The green colour shows the draft above 3 degrees, the red colour below 0 degrees and the blue colour means o deg.

Draft analysis along the tooling axis:

The solid bodies by making proper class B and class C surfaces

Class B surface is created by offsetting the Class A surface to a 2.5 mm distance.

Class B surface is extended.

Class C surface was created from the boundary of the class A surface.

Trimmed Class B surface with Class C surface

Joined the trimmed surface with the Class A surface.

Then using the close surface tool made a solid part of the top substrate.

Creating Flanges

Draft analysis of Solid part

Lower substrate

The extension of the class A surface of the lower substrate is trimmed using a line.

Tooling axis:

Extract a surface and create a point at the centre of the surface.

Created a plan at the point.

Using an intersection an outline of the surface was drawn.

Using a two-point line, two lines were created at a point between the centre point and another point.

A tooling axis was created at that point using the bisecting line.

Draft analysis of Class A surface

Select the customise view parameter and select the material.

Select the Draft analysis tool

Adjust the draft axis dir to the moulding axis using the compass.

Select the lock and select the surface for draft analysis.

The green colour shows the draft above 3 degrees, the red colour below 0 degrees and the blue colour means o deg.

Draft analysis along the tooling axis:

The solid bodies by making proper class B and class C surfaces

Class B surface is created by offsetting the Class A surface to a 2.5 mm distance.

Class B surface is extended.

Class C surface was created from the boundary of the class A surface.

Joined the Class A, B and C surfaces.

Then using the close surface tool made a solid part of the top substrate.

Dog House

Heat stakes

Draft analysis of Solid part

Draft analysis of DogHouse

Draft analysis of Heat stakes

Bottle holder

Tooling axis and draft analysis:

Create a point in the middle of the surface and create an intersection.

Create an axis at that point.

Select the customise view parameter and select the material.

Select the Draft analysis tool

Adjust the draft axis dir to the moulding axis using the compass.

Select the lock and select the surface for draft analysis.

Then adjust the compass to the direction which provides the best draft analysis.

Then right-click on the compass and select lock-current orientation.

Create the tooling axis along the z direction of the lock compass.

The solid bodies by making proper class B and class C surfaces

Class B surface is created by offsetting the Class A surface to a 2.5 mm distance.

Class B surface is extended.

Class C surface was created from the boundary of the class A surface.

Trimmed Class B surface with Class C surface.

Joined the trimmed surface with the Class A surface.

Then using the close surface tool made a solid part of the Bottle holder.

Creating Flanges

Draft analysis of Solid part

Assembled model