Challenge

Week 12- Final project

PPatil Gaurav10 Apr 2023

Week 12-

Final project: Development of a Door Trim panel

Door trim panel is creation of CAD model considering following inputs as like in OEM and tier1 companies

Class A surface is givin but after applying boundries check, it has been found there is some improvement needed to be actioned to get a closed surface. Nominal thickness is taken from the provided master sections.

Based on the knowledge that has been gained by taking the Plastic Design Course by CATIA V5 I have develped Class B Surgaces, Class C Surfaces, tooling axis for every single part, also, I found a strategy to assemble the four seperate parts into one part design by creating engineering features such as Heat Stakes, Ribs, Dog Houses and Flanges.

1- Armrest Part:

a. Class A Improvement:

First I have found that Class A that been givin has open boundries

Class A Improved:

Class B is created by offseting Improved Class A by 2.5 mm as per the master section.

Class C is created by sweeping Improved Class A Surface and it has been trimed with Class B Surface.

Main Tooling Axis and Side Tooling Axis are created in such way to provide drafting.

Close Body is created from the fully close surface:

Applied material details as a wooden Alpine Fir for the armrest body.

In oder to Join the Armrest body with the other bodies, I created 4 Flanges seperatly with counter holes, Flanges are different based on the engineering features will be held. Then these flanges are assembled to the main body (Armrest) by unitrim feature.

Each Flange was created by extracting surface from Class C Surface aidded by Generative Surface. then I applied close surface feature to creat the flange body, Drafted by 0.5 deg, Filletted. Also it is important to mention that the counter holes were created by iso constrained, positioned sketches and then paded it and drafted before it was removed from the main flange.

Proper Sketch Tree for Arm Rest Body:

Publications:

Drafting Analysis:

By applying drafting analysis at 2.9 Deg, we can see must bodies are been cleared. As Green set at 2.9 degree, blues is Zero and less than Zero it is red colored.

2- Lower Substrate:

A- Class A Surface was givin is cheke and found out it is perfectly closed boundries,no further action to be taken.

Class B is created by offseting Improved Class A by 2.5 mm as per the master section.

Class C is created by sweeping Improved Class A Surface and it has been trimed with Class B Surface.

Main Tooling Axis is created in such way to provide drafting.

Close Body is created from the fully closed surface:

Applied material details as a Baige Leaher for the Lower Substrate.

In oder to Join the Lower Sustrate with the other bodies, I will be useing the Lower Subtsrate as the main body where other can be installed accoring to it. All connecting engineering features are created attched to this body while flanges will be conecting this main body to other bodies. two dog houses are created, 8 heat stakes and 2 4 way lockers are created and attached to this body.

Each engineering feature was created by extracting surface from Class C Surface aidded by Generative Surface. then I applied close surface feature to creat the flange body, Drafted by 0.5 deg, Filletted and champherd. Also it is important to mention that features were created by iso constrained, positioned sketches and then paded it and drafted.

Proper Sketch Tree for Lower Substare Body:

Publications:

Drafting Analysis:

By applying drafting analysis at 2.9 Deg, we can see must bodies are been cleared. As Green set at 2.9 degree, blues is Zero and less than Zero it is red colored.

For the engineering features the draft angel is chosen as 0.5 deg as per bellow:

3- Map Pocket:

A- Class A Surface was givin is checked and found out it is perfectly closed boundries,no further action to be taken.

Class B is created by offseting Improved Class A by 2.5 mm as per the master section.

Class C is created by sweeping Improved Class A Surface and it has been trimed with Class B Surface.

Main Tooling Axis is created in such way to provide drafting.

Close Body is created from the fully closed surface:

Applied material details as a plastic for the body.

In oder to Join the Map Pocket with the other bodies, I created 3 Flanges seperatly with counter holes, Flanges are different based on the engineering features will be held. Then these flanges are assembled to the main body (Map Pocket) by unitrim feature.

Publications:

Proper Structural Tree:

Drafting Analysis:

By applying drafting analysis at 2.9 Deg, we can see must bodies are been cleared. As Green set at 2.9 degree, blues is Zero and less than Zero it is red colored.

For the Flanges is set at 0.45 at it is drafted to 0.5 Deg.

4- Bottle Holder:

Class A Improved:

Class B is created by offseting Improved Class A by 2.5 mm as per the master section.

Class C is created by sweeping Improved Class A Surface and it has been trimed with Class B Surface.

Main Tooling Axis and Side Tooling Axis are created in such way to provide drafting.

Close Body is created from the fully close surface:

Applied material details as a plastic for the body.

In oder to Join the Bottle Holder with the other bodies, I created 3 Flanges seperatly with counter holes, Flanges are different based on the engineering features will be held. Then these flanges are assembled to the main body (Bottl Holder) by unitrim feature.

Publications:

Proper Structural Tree:

Drafting Analysis:

By applying drafting analysis at 2.9 Deg, we can see must bodies are been cleared. As Green set at 2.9 degree, blues is Zero and less than Zero it is red colored. As it is shown in the next image that in Class A Surface there is some patches an not be cleared by a draft angel of 3 Deg. it is suggested to be reported back to the drafter in real life but as this is a study project, ill be ignoring this.