Week 12- Final project
OBJECTIVE:
To design the following requirement for the given class A surface and master section sketch.
- Tooling Axis creation & Draft analysis
- Class B surface & class C surface
- Close Body and thicken part
- Creation of additional engineering features.
- Assemble the push pin
Components involved in the Door panel are-
- Lower Substrate
- Door Arm Rest
- Lower Map pocket
- Map Pocket
Automotive Door Panel
The door panel is the interface between the interior of the car and the inner working to the door, and between vehicle occupation and the door. they are expected to meet a variety of Specifications regarding safety, aesthetics, and functionality. Generally door panel is divided into the parts like door armrest, a lower substrate, map pocket, lower map pocket, for easy design. The door currently has an inner full-width panel consist ting of electronic windows central locking system and speakers. these panels typically consist of a foamed core covered with either textiles or plastics.
An additional Consideration is their ability to protect occupation from injury during a side collision where most injuries are inflicted on the chest and pelvis as a result of crushing force of the door
Door Panel Materials
Door panels were formerly made of cardboard with an upholstered interior finish of vinyl, leather, cloth, carpet, or other materials for the decorative trim. modern cars typically have door cards made of plastic, most often using injection moulding as well as incorporating other decorative materials.
components of Door Panels
Class A surface
Class A surface for the Automotive door panel is received from the stylish team, In the automotive Industry for Class A surface Separate team is allowed to design Class-A surface this is the first input for design for plastic parts
before proceeding to further design first check the class A surface if there is any gap then modify the class A surface
Tooling Axis
Creating a tooling axis
The tooling direction is used to find the direction in which the parts are removed from the core and cavity by using a tooling axis draft analysis is formed for each component.
MAP POCKET
Creating a tooling direction on the map pocket, create a point on the class A surface respectively as 0 value, then create a line with respect to the Y-direction. Also, check a draft analysis for the given Class-A Surface.
before proceeding to further design first check the class A surface if there is any gap then modify the class A surface
Tooling Axis
Creating a tooling axis
The tooling direction is used to find the direction in which the parts are removed from the core and cavity by using a tooling axis draft analysis is formed for each component.
MAP POCKET
Creating a tooling direction on the map pocket, create a point on the class A surface respectively as 0 value, then create a line with respect to the Y-direction. Also, check a draft analysis for the given Class-A Surface
OUTER MAP POCKET
Creating a tooling direction on the map pocket, Create a point on the Class A surface respectively as 0 value than, create a line with respect to the y-direction Also checking a draft analysis for the given Class-A surface.with draft'
But performing a draft analysis for class A surface of lower map pocket some area shows a blue surface as 0 degrees here we don't have to right to modified class A surface so we need to inform to class A team to provide a draft angle.
LOWER SUBSTRATE
Creating a tooling direction on the Map pocket, Create a point on the Class A surface respectively as 0 value, then create a line with respect to the y-direction also checking a Draft analysis for the given Class A.
DOOR ARMREST
Creating a tooling direction on the Door Armrest, Create a point on the Class A surface respectively as 0 value, then create a line with respect to the y-direction also checking a Draft analysis for the given Class A.
CLASS B SURFACE---
OUTER MAP POCKET
LOWER SUBSTRATE
DOOR ARMREST
Finally by doing an offset of 2.5 mm by using master section Distance. We have got Class B surface
CLASS C-SURFACE
By extracting the boundary of class c surface and at the edges then make into them by using a smooth curve and sweep command to make c surface.
OUTER MAP POCKET:
After trimming with Class C with Class B Surface and then joining with Class A surface, finally, we get the closed surface to know that use boundary option it shows as the selected body is closed.
LOWER SUBSTRATE:-
DOOR ARM REST:
After extracting a boudary of class A surface then extrapolates a surface of class B surface up to a certain distance to trim with class A surface to C surface. Finally closed surface is formed.
DRAFT ANALYSIS FOR CLOSED SURFACE
MAP POCKET
In this figure, the minimum draft angle for all faces should be 1.45 deg or above, in this colour, the scale shows a draft angle of 2.9 or above. blue shows between 0 to 1.45deg and red colour show a negative draft angle, as per the above figure some faces are green, blue, and red as well hence the surface is not cleared the draft analysis at the red faces and blue faces using the main tooling axis. the minimum draft angles at the blue face are 0 deg so the class A surface needs to be given a proper draft, and required changes are forwarded to the stylish team for modification.
LOWER SUBTRACT
DOOR ARM REST
In the door, the arm rest main tooling axis clears the upper surface as shown in the figure as green color but under the cut, a tooling axis is required for the side core tooling axis is created.
ENGINEERING FEATURE / B SIDE FEATURES
In the Door panel, all the parts are attached together by using B-side features like heat stake , Screw bosses, 4-way locators, flanges, and a Dog house.
Flanges are attached to the map pocket, outer map pocket, arm rest. The remaining features are placed on the lower substrate which will act as central parts for all the components it is mainly used to joint the remaining parts.
Flanges
All the flanges have been created by following the given master section. the thickness of the flanges is 2.5mm, the draft angle is 0.5 deg applied to all the flanges. Edge fillet of 5mm applied to sharp corners. slots for locators and heat stakes have been created onto all the flanges.
DOG HOUSE
The dog house is an engineering feature used in plastic design. Dog houses are used as supporting features sometime other engineering features like snaps, locators, etc are mounted on them to increase their strength. Dog houses are subjected to draft analysis to prevent breakage of the components during ejection from the mold cavity. dog house and other engineering components are built on the B surface.
