Week 12- Final project

AIM :- To create a CAD model for door trim panel's parts by considering the given inputs of class A surface along with master section by following the design rules followed in OEM and tier1 companies.

Objectives :-  

• To create individual tooling axis for the parts and perform draft analysis on the class A surface
• To create the class B and class C surfaces from the given class A surface
• To form a solid geometry by combining all the surfaces
• To decide an attachment strategy for the part and create engineering features in reference from the master section provided
• To perform draft analysis on the solid part model with all engineering features
• To assemble all the components togehter to obtain the final trim

Given Data :- 

• Class A Surface for Door Trim Panel -

As we know in automotive industry there are complex products that we have to design but this is not possible with simple sketches for that we need Class A Surface.

The A-surface or the styling surface is first checked for any gaps and other issues in its surfaces. This Surface acts as the input surface so any correction to be done should be with approval from the styling team or done by them. A- perfect surface is the one when a boundary is created, the lines are only on the edges of a component and its holes or cutouts as shown below.

Steps Follwed for Completion of Project :-

The door trim panel is created by follwing steps -

1. To check given Class A surafces for any modification.
2. To segregate given surafces into separate part body namely Lower Substrate , Arm Rest , Map Pocket , Bottle Holder.
3. To work individually on each part.
4. To create tooling axis for part.
5. Draft analysis on class A surafce.
6. Creation of class B and Class C surafce.
7. Craete closed body from Class A , B and Class C surface.
8. Follwed same procedure to craete all parts .
9. Then create attachement features for all parts.
10. Then do Draft analysis on final parts and then constrain them for assembl

•   Class A Surface -

1. Check Given Class A Surafce for improvement                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                         Given class A surafce is not as good as needed . we have to informed styling team for improvement.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                 
2. Improvement of Class A Surafce -                                                                                                                                                                                                                                                                                                                                                                                                                                                                                         

            

    As shown in above image I have improved given class A surface in surafce workbench by using surafce operation such as extract, extrapolation , trim etc.

• Creation of Tooling Axis - For moulding of Arm Rest we need two tooling axis. Some area get cleared with first tooling axis and reamaining with second one.

• Draft Analysis of Class A - 

From above draft analysis we noticed that there is lot of space for improvement of class A surafce. We have to request stlyling team for class A modification.

• Creation of Class B Surface -

Class B surface is created by offseting class A surafce by 2.5 mm as per the mastersection. After offseting some area not get offseted , there patches formed. This patches are closed by surface creation features such as fill , multisection , blend etc.

•  Creation of Dog House 

DOG HOUSE -

• The two main purposes of a dog house are to avoid sink marks and to house various other engineering features like screw boss, locators, push clips etc.
• In this case, the dog house is designed to house the push clips and the 4 way locator. The dog house designed for the push clip features a slot on the top face to accommodate the push clip
• The dog house should follow certain design rules which are stated below

• Doghouse wall thickness at the intersection of the part wall (C) should be 40% or less than the main wall stock (T).
• The height of ( B ) should be between 3.0 – 6.0 mm
• Outer surface of dog house must have a draft angle of 3 degrees
• Inner surface of dog house must have a draft angle of 0.5 degrees

 

 Draft Analysis on Dog House -

 From above drfat analysis we noticed that outer surfaces of dog house have minimum draft of 1.5 degree and inner surfaces with minimum draft of 0.5 degree.

CONCLUSION :- 

From this project I have leraned how to create CAD model for plastics parts by considering design rule. By doing this project on Catia V5 , I get very well familiar with part workbench ,surface workbench , Assembly workbench. Also I get confidence in handling different features of all workbenches. Along with this , I get idea of how to design a part by considering manufacturing and assembly aspect.