DESIGN OF CAR DOOR TRIM PANEL ARM REST (A surface to B surface conversion/ Draft analysis check/Tooling Direction for A surface )

DESIGN OF A CAR DOOR ARMREST ( A SURFACE TO B SURFACE CONVERSION )

OBJECTIVE:

The objective of this project is to

• Clean the given A-surface for any erroneous surface elements
• Offset the surface to the given part thickness
• Ensure the offset surface is free of any sharp edges
• Tooling feasibility of the A-surface to be studied using draft analysis

GIVEN:

The A-surface and the reference part of the Door Trim were given. The part thickness given is 2.5mm.

DESIGN METHODOLOGY:

1) A-SURFACE CHECK

We check the given styling surface for any error in the surface elements. To do this we have to first disassemble the styling surface and then join it with the merging distance of 0.001 mm. This will show where the surface elements are weak. These weak sections have to be improved. The joined surface is then given as an input to the A-surface geometrical set.

2) A-SURFACE IMPROVEMENT:

All the sharp edges in the surface were removed and a cleaned surface was obtained. We can use boundary command to detect and error on the surface.

3) TOOLING DIRECTION CHECK

The tooling direction is used to find the direction in which the part is ejected out of the mold. The draft on the part should be positive in order to manufacture the part easily. The draft angle should be positive with respect to the tooling direction. To find the tooling direction we first need to clear the walls of the plastic part. We perform draft analysis on this line.

Now we rotate the axis to find where most of the part is getting cleared.

The minimum angle here is 1.623 degrees.
Here we can notify that the wall draft should be increased and the slope should be decreased.

4) B-SURFACE GENERATION AND IMPROVEMENT

The B surface is that portion of the plastic part which is not visible on the outside. But the quality of the B-surface is what affects the quality and manufacturing of the part. We need to ensure that the B-surface is at the required offset and free from any surface errors.

5) C-SURFACE

C surface is the closing surface of the plastic part. We need to ensure that the surface has no sharp edges and has minimum or no surface elements with a draft angle less than the specified. The C surface is created by using the TOOLING DIRECTION.

6) PLASTIC PART

All the above surfaces are joined to form a close body.

7) DRAFT ANALYSIS ON THE PART

Some sections of the closed surface are partially clearing the draft analysis. The minimum draft angle reached is 0.68 degrees.

8) SPECIFICATION TREE MAINTENANCE

FINAL BODY

CONCLUSION

The required plastic part has been developed from the given A-surface while following all the necessary design guidelines. Tooling check and draft analysis study have been performed.