Automotive Interior Trims Design

Automotive Interior Trim Overview

Automotive Interior Trim Overview
The Automotive Industry
The automotive industry is an extremely large, diverse, globalized organization encompassing many business facets, employing hundreds of thousands of people all with one goal: to produce a world-class vehicle. This complex structure must always stay one step ahead of its competition with quality, customer satisfaction, and continued excitement built into its products. Automakers conduct marketing studies and host consumer clinics where the public analyzes and tests new vehicle engineering options and styling. Engineers and designers then incorporate this critical information into a vehicle’s design. Another important area considered is government safety standards. Most automakers design beyond these safety standards creating safer, stronger, and more reliable vehicles. Designing a vehicle that meets customer satisfaction creates customer enthusiasm and loyalty.

 

Automotive Interior Trim
The Automotive Interior Trim course concentrates on plastic part knowledge. You will learn in this course how to create plastic parts, and about mold design and the types of molds used for different interior parts. It’s helpful to have a basic knowledge of crash standards.

Topics include:

Plastic Fundamentals
This area explains concepts related to plastic industry, common CAD functions used when designing a plastic part, and common plastic terminology. Learning the appropriate design rules when creating plastic parts reduces the design rework required to design correctly a plastic part.

We introduce a process for designing plastic parts in a CAD system, the options to use when designing plastic parts, and why to use specific functions. Following this process helps you concentrate on the design issues of a part and not fumble with the operation of the CAD system.

Plastic Design and Tooling
It’s important to understand molding practices and terminology in order to communicate effectively with the tooling vendor. We explain different molding practices, machine types, and design issues.
Interior Trim Case Study
You reinforce the concepts and practical applications explained throughout the course by working through the Radio Face Plate case study. This case study starts by creating the cosmetic shape that is driven by industrial design from IGES data. You recreate this data to make a feature-based CAD model and then add the mechanical features to provide strength and attachment to the other components. After completing the model, you will be tasked to make a series of design changes on the model.

Styled Parts in Automotive Interior Trim

Styled Parts in Automotive Interior Trim
Overview:  This course explains how to make basic plastic parts that are injection molded. These parts have a uniform thickness, drafted walls, and fillets to provide better flow for the material. In the automobile, you find these cosmetic, styled parts on the interior of the automobile. The majority of the plastic industry revolves around making cosmetic-like parts.

Creating styled parts usually involves sculpting a solid model using various surfacing operators. You should be familiar with features such as Multi-Section and Sweep, and as you may know, they can be tricky to use. We explain how using these features provide the best control over the shape of your part. You also learn to use sketches and advanced curve operations to produce the best possible quality surfaces.

Translating CAD data is becoming a common occurrence, therefore learning how to create a solid model from imported data is essential. Translating complex styled parts can be quite difficult. We’ll show you some tips and techniques to help you in manipulating these solid models.

Assemblies and Parametric Linking

Assemblies and Parametric Linking
Overview:  Nearly every design involves an assembly of parts. Usually the next step after you model a single part is creating an assembly. This course explains basic assembly concepts along with common ways to define parametrically the location of assembly components.

Assembly Constraints can be tricky with plastic parts. The methods traditionally taught are not conducive to effectively defining relationships between plastic parts. We explain the best techniques that take advantage of assembly constraining.

Parametric linking is also explained. This is a method of linking geometry between components of an assembly. Using parametric linking with styled parts can be a big time-saver. This is especially true for parts that have the same styled surface. For example, Parametric Linking lets you use a surface in multiple parts by allowing you to make a copy of the surface rather than having to recreate it.

This course also contains resources for assembling plastic parts. We look at the secondary operations available for plastic parts such as machining. Assembly methods specific to injection molded parts are also covered. Ranging from press fits, snaps, and fasteners to welding, you learn the advantages of each.

Injection Molding

Injection Molding
Overview:  Injection molded parts are manufactured just as the name implies. Plastic is injected into a mold to form the part. While this is a simple enough concept, injection molding can be a complicated process. In order to successfully design plastic injection molded parts it is useful to first learn a little about the way this process works.
The Mold Machine
The preceding figure illustrates the basic parts of a mold machine.

The plastic material starts in granular form. Operators feed these pellets into a hopper, which a rotating screw pushes through a long cylinder known as the heating cylinder. This cylinder is a barrel containing the plastic material. Surrounding the barrel are heating elements to melt the material. This molten material, commonly known as melt, is injected into the mold.

A mold has two halves. One half attaches to a stationary platen while the other attaches to a moving platen. The melt fills the mold, then cools to form the part. The moving platen then travels away from the stationary platen and the mold base ejects the part.

 

The Mold
There is more to a mold than two halves. While there’s too much to cover in this course, it is beneficial to learn a few basic things. Let’s look at a basic two-plate mold.

Both the top clamping plate, at the figure’s far right and the “A” plate mount to the stationary platen on the mold machine.

In the center of the top clamping plate is the sprue bushing. The sprue bushing connects the nozzle on the heating cylinder to the mold. This allows the molten plastic to enter the mold.

The “A” plate contains the cavity of the mold. The cavity is a depression that forms the outside of a part. This essentially constitutes one half of the mold.

The “B” plate contains the core of the mold. The core is a protrusion that forms the inside of the part, making up the second half of the mold. This half attaches to the moving platen that pulls the part out of the cavity.

Once the moving platen has separated the mold halves, the part ejects from the mold. The ejector housing, at the figure’s far left, contains a moving plate, the ejector plate.

Attached to the ejector plate are pins. The ejector pins, also known as knockout pins, push the part off the mold core.

Once the part ejects, the moving platen closes the mold, ready to form a new part. The time it takes to make one entire part is known as a cycle. The cycle time is very important in the design of a part. A shorter cycle time means that more parts can be made on a given day, resulting in a higher production rate.

 

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