Week 12 - Project 6 - Master Section Development

DESIGN OF B-PILLAR THROUGH MASTER SECTION DEVELOPMENT

AIM :

To design the B-Surface interior trim of B-Pillar with the reference of A-Surface & master section using CATIA-V5, Also to develop the attachment feature of parts which followed in OEM design standards.

OBJECTIVE :

• To design the solid part by the A-surface & master section.
• To create the tooling axis of B-pillar & Analyse the draft angle of component.

DESCRIPTION :

This project which shows the detail analyse of design , Master sections , practical knowledge on plastics with core & cavity And Tooling Axis & draft analysis.

Pillars :

Pillars are the vertical or near vertical supports of a car's window area or greenhouse designated respectively as the A, B, C or (in larger cars) D-pillar, moving from front to rear, in profile view.The consistent alphabetical designation of a car's pillars provides a common reference for design discussion and critical communication.

A-Surface :

Master Section :

Master section which gives the Proper guides for design requirement to the design engineers.

PLM Of Automotive industries :

Design life cycle of automobile industries :

• Concept Sketch often freehand, that are used by designers such as architects, engineers and interior designers as a quick and simple way of exploring initial ideas for designs.
• Styling Class A design from concept sketch where industrial designers develop their design styling through the A-Surface, the physical surface the end user can feel, touch, see etc.
• Feasibility Check is an assessment of the practicality of a proposed project or system. A feasibility study aims to objectively and rationally uncover the strengths and weaknesses of an existing parts or proposed venture.
• Concept Validation is before getting a product into production and launching it to the marketplace it's critical to determine its acceptability to the marketplace.
• New Product Design which works on 3 basic principle

1. Analysis
2. Concept
3. Synthesis

• Development is a process that creates growth, progress, positive change for the automobile parts.
• Prototype built the visual model for presentation or the knowledge (e.g) Clay modelling.
• Design Validation is a final testing process of product which you design.
• Pilot Production is also the process of validating the product with less amount of production.
• Mass Production is takes place after the validation from the customer.

Tooling Axis :

the tooling axis which gives the proper direction of the Core & Cavity for moulding the plastics components. In the part shown below the tooling direction which shows was the proper direction for the core , cavity & lifter direction. the dotted lines which shows the tooling direction for the core , cavity & lifter.

here the Rose surface is the A-Surface & the brown is B-Surface.

B-Surface :

• The B-Surface was created with the thickness of 2 MM.
• The uniform thickness ensure that the part designed does not form Sink mark & Flow lines.

Attachment features :

• As from the master section the attachment features are Dog House & 4Way Connector.
• In the B-Pillar design the dog house & 4 way connector was created as per the OEM design Standards.
• The below image which shows the intersection of dog house & 4 way connector.

• The below image shows the solid part designed with thickness of 2 MM & the attachment features are designed as per the master section & OEM design Standards also the tooling directions.
• The ribs are created at a distance of 50 MM apart.
• The attachment features which follows the 3-2-1 taylor's principle.

Draft Analysis :

The ribs , 4 way connectors & the dog house has the draft angle of 0.5 deg.

Draft analysis for core,

Draft analysis for cavity,

Draft analysis for Attachment features,

Here the red colour shows the draft angles are below 3 deg, because the min draft angles for attachment feature is 0.5 deg.

CONCLUSION :

Thus to design the B-Surface interior trim of B-Pillar with the reference of A-Surface & master section, Also to develop the attachment feature of parts which followed in OEM design standards is completed successfully in CATIA-V5.