Car Door Trim assembly

Last crawled date: 1 year ago

AIM:

To design a Door Panel of an Automotive using CATIA V5.

OBJECTIVES:

To create an assembly and organize different surfaces of the given class A surface into different parts of the door trim panel. To create a tooling axis and perform a draft analysis on the class A surface of each part. To create class B, class C surface, and close surface for each part. To perform draft analysis on the close body of each part. To create engineering features (Heat stakes, Locators, Dog House) to join the parts of the door trim panel together. To assemble push pins to the door panel.

THEORY:

A door panel, also known as a door card, is an insert that covers the interior components of a vehicle's door. Modern cars often have door cards that are constructed of plastic and incorporate other decorative elements, with injetion molding being the most common method. Other features that add to the vehicle's aesthetic, functionality, and ergonomics are usually included in the door panel. Armrests, switches, or other controls for the windows and locking mechanism, convenience lights, speakers, storage compartments, and other features are examples of this..

PROCEDURE:

Class A surface of a door panel received from the styling team. In the automotive industry dedicated team is allocated to develop class A surface using sketches followed by ideation. Class A surface is the first input given to the plastic designer.

A) CLASS A SURFACE OF A DOOR PANEL
FRONT SIDE:
BACK SIDE:
B) CREATION OF AN ASSEMBLY:
Door Panel class A surface has the following parts -

Door Arm Rest
Lower Substr
Map Pocket
Bottle Holder


Door Arm Rest
Creation of tooling axis
The line has been created using the line command. The point-direction option is used to create the main tooling axis in the z-direction.

Draft analysis of Class-A surface on Tooling axis direction:
Change View Mode Customization to Material mode.
Go to INSERT--->ANALYSIS--->FEATURE DRAFT ANALYSIS and move the compass to the moving Axis.
Change the range to 3°. Apply the settings as shown in below image.
The input Class A also has walls having negative angle to the tooling axis.
This can be an issue while manufacturing the component as it would be very difficult to draw from the molds.
So, this design needs to consider Various Side Tooling Options.
Here also we can see that some faces are not clearing draft analysis and it is due to the improper class A surface and we have to imform our styling team to modify the class A surface.