Week 12- Final project

AIM:

Creation of CAD model considering following inputs as like in OEM and tier 1 companies

1. a) Class A Surface

2. b)Nominal thickness:Refer to master sections

3. c)Attachment strategy

Use Pushpin with Dog house for lower substrate - Door panel attachment

Use heat stakes for part to the part atachment.

ABSTRATC:

The project deals with the explanation of steps and procedures followed while developing the door trim panel of a car using CATIA V5.

Using the given class A surface tooling axis, class B surface, class C surface were created, and after forming the silod body from that the flanges and the B side features such as Dog house, Push pin, Heat Stakes, etc were built. And finally, the draft analysis is also done on the components to check the manufacturability of the components.

INTRODUCTION:

Front Door Panel

Door panels serve as an inferface between the interior of the car and the inner workings of the door, and between vehicles accupants and the door.They are expected to meet a variety of design specification regarding safety, aesthetics, and functionality. In addition, they are expected to continue the material theme of the dashboard and the pillars while concealing intricate electrical and mechanical components for operating locks, windows, and other features.

In this project, an inner car door panel is given with class A, to create the door trim panel it is divisded into sub-parts namely, a lower substance, inner map pocket, outer map pocket, and door armrest.

Given Input:

Sub Division:

Dividing the given surface into 4 parts to prepare each part individually for manufacturing and then assembling. Yhe parts are created according to the master section given along with input.

1. LOWER SUBSTRATE:

Class A and Tooling axis:

Multiple extracyed the subparts of the surface for lower substrate and using join command created a single Class A surface. Some parts were not propely alinged so by joining command and sub-elements to remove that parts and using multi-section surface to create a class A surface with no defects.

* Create a point on class A surface to move the main tool for components creation on the base surface.

* Mark an axis over the point created with the same direction as the main axis.

*Bisect those two lines over the axis point we created.

Draft analysis:

*After Tooling axis selection the features draft analysis option from the Insert option.

*Select the element to analysis.

*Next clisc on Use the compass to define the new current draft direction option and make it aling with the tooling axis by dragging it to the axis

*If the color appears blue just click the invert option on the right side of the draft direction axis button.

Class B:

Using the offset command and taking reference from the master section provided an offset of 2.5mm is given for the thoickness of the part.

Since fillets were creating problems for surface so byh using the multi-section surface command the remaining surface were created.

Class C:

Here all the outer boundaries are extracted according to the requirements.

Using sweep command with the draft direction of 3 degrees we get class C surface.

The sweep was created in patches as connectivity error was occuring each sweep was extrapolated and trimmed togather to create on single class C surface.

Final Trim:

Finally all the surface were trimmed togather as shown below

Draft analysis:

The above class A draft analysis gere also after creating a closed surface body, the draft analysis is done.

Similar to the above process all class A, tooling axis B, C and Final trims are created for all the other surfaces.

OUTER MAP POCKET:

Class A Surface and Tooling Aixs:

Draft Analysis Class A Surface:

Class B Surface:

Class C Surface:

Final Trim:

Draft Analysis:

INNER MAP POCKET:

Class A Surface ans Tooling Axis:

Draft analysis:

Class B Surface:

Class C Surface:

Final Trim:

DOOR ARMREST:

Class A Surface:

Draft Analysis:

Class B Surface:

Class C Surface:

Final Trim:

Draft analysis:

MOUNTING FEATURES AS PER DESIGN GUIDELINES:

Flanges:

A flange is a product ridge, lip, or rim, either external that serves to increase strength (as the flange of an iron beam such as an I-Beam or a T-Beam); for easy attachments/transfer of the contact force with another objects.

Below in the sketch for the two flanges I selected for plastic parts joining.

According to the design rule, ther section provided the flange thickness should be equivalent to the plastic component for rigidity and strenght.

A minimum draft of 0.5 degrees is used as per the model.

Sketchs:

Part body:

DOG HOUSE:

The dog house is an engineering features used in the plastic trim design. Dog house are used as supporting features. Sometimes other engineering features like snap, locators,etc., are mounded on them to increase their strenght.

Part Body:

The Draft angle is use as 1.5 Degrees for the Dog house

The shell is used as 1.5 mm for the dog house

And the Fillets are used as 1mm for the dog house

HEAT STAKES:

Heat Stakes is a pulsed-heat process to join two or more parts out of which one at least is made of plastic. The process is to deform the plastic materials using heat and force at a set process time. The bond is made by partially de-forming the plastic parts to fix the other.

Sketches:

Part Body:

Lower Substrate:

Here I used two dog house with push pins to firmly attach the lower substrate to the metal body of the door by creating a traingle that restricts the degree of freedom in 3 axis, further more, the push pins totally lock the remaining degress of freedom.

DOOR ARMREST:

According to the master section given need to use flanges to attach the door to the lower to the lower substrate and since I don't need to design the upper substrate, therefore, gthe flange for them are not shown in the figure.

Inner Map Pocket:

Following the principle of 3-2-1, I used 2 critical locators for attaching the inner map pocket to the other parts with one flanges to the inner map pocket and one part to the lower substrate of the door panel. Since no dog house is neede, the part is supposed to be attached to only parts via heat stakes only.

OUTER MAP POCKET:

For the outer map pocket since already 3 attachements were provided via the inner map pocket but as the only part that is going to be joining to the main door panel is the lower substrate so we need to strategze accordingly so i created flanges to join then parts to the lower substrate so that the vibrations while driving is minimized as low as possible.

Finally a body with all the features:

CONCLUSION:

The door trim panel was successfully created with all the design rules taken into considerations for features attachments and the main part was created using the provided input Class A Surface