Week 12- Final project

Final Project: Door Panel Design in CATIA V5

Objective

To design a door inner panel in CATIA V5, incorporating:

• Draft Analysis (for manufacturability)
• Tooling Direction (Mold pull direction)
• Class A, B, and C Surfaces (aesthetic and structural surfaces)
• Closed Surfaces & Parting Lines (for Mold design)

What is a Door Inner Panel?

The door inner panel is a structural and aesthetic component of a car’s interior. It serves multiple functions:

• Enhances visual appeal.
• Conceals wiring and internal components (e.g., speakers, window mechanisms).
• Comprises sub-parts like the upper/lower substrate, armrest, bottle holder, and garnish, ensuring ergonomic comfort and functionality.

Design Methodology

Using provided Class A surfaces and master sections; we developed solid models for:

1. Armrest
2. Upper Substrate
3. Lower Substrate
4. Bottle Holder

Each part was designed with manufacturability in mind, ensuring proper draft angles and moldability.

Step-by-Step Design Process

1. Armrest Design

• Step 1: Copied the Class A surface and linked it to a new geometric set.
• Step 2: Conducted draft analysis—identified undercuts requiring side cores in the Mold.
• Step 3: Generated Class B surfaces (2.5mm offset from Class A) and Class C surfaces (structural supports).
• Step 4: Used Multi-Section Solid and Fill commands to refine complex geometries.
• Step 5: Combined surfaces into a closed solid body and validated with draft analysis.

Result: A manufacturable armrest with proper Mold considerations.

2. Upper & Lower Substrate

• Class A Surfaces: Reviewed for aesthetic continuity.
• Class B & C Surfaces: Created with offsets and joined for structural integrity.
• Draft Analysis: Confirmed moldability (some areas required side actions).
• Closed Solid Bodies: Ensured watertight geometry for tooling.

3. Bottle Holder

• Followed the same workflow:
• Draft analysis → Class B/C surfaces → Solid modelling.
• Added ribs for reinforcement.

Class B Features for Assembly

1. Doghouse (Snap-fit Feature)

• Purpose: Secures panels using push pins.
• Design Parameters:
• Thickness: 3mm (for stress resistance).
• Ribs: Reinforce push-pin mounting points.
• Draft: 0.5° (for easy ejection).

2. Heat Stakes (Permanent Joints)

• Purpose: Bonds parts via heat welding.
• Design Considerations:
• 0.5° draft (max recommended).
• Used to attach armrest, bottle holder, and substrates.

Final Assembly

• Components were assembled using:
• Axis Constraints (aligning circular features).
• Offset Constraints (positioning relative to reference planes).

• Push pins were added to Doghouse features for secure fastening.

Conclusion

The door inner panel was successfully designed, meeting:
✔ Aesthetic (Class A) requirements
✔ Structural (Class B/C) integrity
✔ Manufacturability (draft, tooling direction, parting lines)