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1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1526 “CONCEPT VALIDATION AND DESIGN SYNTHESIS OF CAR DASHBOARD AS PER PLASTIC TRIM STANDARD” Jayesh Sudhakar Sarode1, Vijay Liladhar Firake2, Dr. Atul Patil3 1MTech -Scholar, Department of Mechanical Engineering JTMCOE, Faizpur. 2Assistant Professor, Department of Mechanical Engineering, JTMCOE, Faizpur 3Managing Director, IKSC Knowledge Bridge Pvt. Ltd. Pune ---------------------------------------------------------------------***---------------------------------------------------------------------- Abstract - The evolution of dashboard has led to increased vehicle occupant comfort and convenience as new systems become available. The project work aims to develop the work to apply theoretical and practical tools/techniques to solve real life problems related to industry and current research in this project automobile (Car) dashboard upper cover is selected for a design. For doing so conceptual design tool is used. I am created a five different concepts using different benchmarking & brainstorming. Select a best option using different tools in six sigma like trade off analysis. Three- dimensional CAD software (such as CATIA)isusedtodevelopa CAD model same as concept. The aim istoachievetheessential function at the lowest overall cost while maintaining customers’ optimum value assurance. In this project I try to develop a such dashboard design which follow a design guidelines, And analyze and discuss the results to Obtain valid conclusions which follows a design Standards. Key Words: Conceptual design, Car Dashboard design, concept validation, Plastic Trim Design.… 1. INTRODUCTION Automotive dashboard is one of the most important parts in vehicle interior parts. Automotive manufacturer need to consider the quality, cost, reliable design and safety of the product when study the conceptual design of automotive parts. Ergonomics design criteria is considered during design process. In the context of the dashboard, ergonomic design will ensure the display in the instrument cluster can be easily seen and the vehicle control system can be easily reached by the driver. Plastic part dashboard is designed by following Plastic trim design guidelines as well as DFM (Design for manufacturing) and DFA (Design for Assembly) guidelines. Designing plastic parts and components involve implementing wide knowledge from different engineering areas. A successful design process requires a coherent teamwork between a designer and other specialist such as a tool designer and a manufacturing operator. Regardless, a part design often passes sequentially from concept development to the manufacturing phase with features that unnecessarily complicate production and add costs. It can result to a decreased product performance and a premature failure. For a plastic part to maintain quality of part many factors are consider like design,tooling,processing,handling and assembling, part estimate life, etc. Table -1: Requirements relative to a corresponding life cycle stage. Life cycle stage Requirements Design Specified and understood part behavior under anticipated service conditions Consideration for the whole life cycle Agency approvals Tooling ProperdocumentationIntegratedtooling principles Adjustment allowance Manufacturing Effective cycle-time Proper mold filling Material availability Assembly and handling Error-free assembly, Practical handling Service A product that functions as intended; Sufficient strength Impact resistance Stiffness Friction Dimensional accuracy Surface quality End of Life Minimal environmental impact Table -2. influences relative to a corresponding life cycle stage. Life cycle stage Influences Design Part geometry Material selection Manufacturing Short-term mechanical stresses Long-term mechanical stresses Thermal stresses Environmental stresses Tooling Part geometry Material selection Production volume Manufacturing Part geometry Material selection Assembly and handling Part geometry Material selection Service Part geometry Material selection Manufacturing Short-term mechanical stresses Long-term mechanical stresses Thermal stresses Environmental stresses End of Life Part geometry Material selection
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1527 2. METHODOLOGY The standardized process used. The idea of dashboard design can be illustrated in a few conceptual designs. To choose final design, the best design selected using the concept score used. The CAD modeling of final design was performed by using CATIA P3 V5- 6R2017 software. To generate conceptual designs firstly collect a data who is customer and what is a need of customer? Called voice of customer, using market survey collect this dataand take itas a input to design a new product or upgrade a product by using engineering tolls and knowledge. Table -3 Voice of Customer causes of failures - • 45% Design • 20% Poor specification and material selection • 20% Processing • 15% Misuse Fig -1: Distribution of causes of failures. 3. CONCEPT GENERATION From the engineering comment we are generate a concept. The most suitable design was selected using concepts scoring. The maximum point was selected as the final design. Concepts are generated using various methods like benchmarking, brainstorming, Establishing the primary Concept, Developing Alternative to Primary Concept, Working through concept Contradiction etc 3.1 Benchmarking Fig -2: Concept 1 3.2 Brainstorming Fig -3: Concept 2 VOC (VOICE OF CUSTOMER) Engineering Comments Low Space Utilization Reliable design/ flexible design Reliable design/ flexible design Good ergonomics Structure / geometry / mechanism / Attractive Design Plastic Trim Controls & Electronic functions should be convenient to use Distance to access the controls Good ergonomics Design not be overdesigned Less Weight Choose of Material Durability Rigid and strong material Comfortable and convenient System Good ergonomics while dashboard Design it must follow plastic Trim guidelines Safer Design & Easy to Manufacture Dash board noise and vibration should be less in the cabin Packaging
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1528 3.3 Establishing the primary Concept Fig -4 Concept 3 3.4 Developing Alternative to Primary Concept Fig -5 Concept 4 3.5– Working through concept Contradiction Fig -6 Concept 5 4. CONCEPT VALIDATION The concept validationkeycriteriaisfigureoutfromvoice of customer and automotive plastic trim standard. Like plastic part is designed for manufacturing in injection molding forthat part shouldbe clear in draft for partejection and follow tangency all over the part to aesthetic surface. It is a cyclic process that consists of sequential steps, which are simply stated the following: • Melting of the plastic granules and conveying the melt towards the injection unit. Ashot, predefined amountofmelt is injected into the mold to produce the part. • Injection of the plastic melt into the mold under a high pressurethrough thegate.Gatelocationhasagreatimpacton mold filling and to the embodiment of a part. Design features such as wall thickness and ribs influence on the mold filling. • Cooling andsolidifying of the plastic in the mold,whilea part is also shrinking. Differential shrinking causes visual defects. • Ejection of the molded part from the mold by ejector pins or rings. A draft angle in the wall of a part facilitates ejection. To Validate a concept In trade off analysis is done on design Alternatives are compered by following manner. Table -4 Tradeoff Analysis Pugh Matrix Compare Alternatives Key Criteria Importance Rating Alternative1 Alternative2 Alternative3 Alternative4 Alternative5 Product reliability 8 - S + + S Volume and Packaging 7 + - + - S Design for strength and stiffness 8 S - S + + Design According to DFM 9 - + + S - Design According to Aesthetic 7 S S + - + Design According to DFA 9 + - + S - Design for Safety 10 + + S + S Less weight of Product 6 - S + - + Low Cost 7 - S + S - Light weight 8 S - + - + Easy to manufacture 9 + S + + S Design Based on Standards Of Plastic 10 - - S + S Process parameters 6 - + - - + Long Service Life of Product 5 S - S S - Less No Of Component 7 + S - - - Clear in Draft With MTD 10 - + + + S Sufficient area and volume for driver and Passenger 9 S + + - + product should match vehicle Appearance 8 - - + S - Follow A Surface Tangency 10 S S S + + ergonomics design 7 + + + S S design for aesthetics, color gradation, styling 8 - - + - S Reliable design/ flexible design 9 - + S + - Concept Selection Legend Better + Same S Worse -
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1529 Sum of Positives 6 7 14 8 7 Sum of Negatives 10 8 2 8 7 Sum of Same 6 7 6 6 8 Weighted Sum of Positives 49 60 112 81 63 Weighted Sum of Negatives 13 58 54 0 0 For Best Outcome Select Best Weighted Sum of Positive outcome 112 So For Best Outcome Select Best Weighted Sum of Positive outcomewhich is Alternative 3 is selected for furtherStudy. 5. VISUALIZATION CONCEPT TO CAD The visualization process is a process in which concept design sketches convert to CAD model. The visualization process contains three stages. The first stage is mainly developing a visual structure, creating wireframes and delivering a wide range of sketches, while in the next style development stage, the general look is created based on the first stage and the function hierarchy structure. In the last visualization stage the whole designisrefinedbylookinginto details in CAD model. Following factors are consider in while considering concept to CAD • Required strength (including impact and flexural strength) • Specified range of service temperatures • Exposure to chemicals and harsh environments • Appearance requirements • Dimensional tolerances • Required agency approvals • Processing method • Assembly method Fig -7 Design guidelines for plastics. Injection Molding Design Guidelines- Much has been written regarding design guidelines for injection molding. Yet, the design guidelines can be summed up in just a few design rules. • Use uniform wall thicknesses throughout the part. This will minimize sinking, warping, residual stresses, and improve mold fill and cycle times. • Use generous radius at all corners. The inside corner radius should be a minimum of one material thickness. • Use the least thickness compliant with the process, material, orproductdesignrequirements.Usingtheleastwall thickness for the process ensures rapid cooling, short cycle times, and minimum shot weight. All these result in the least possible part cost. • Design parts to facilitateeasy withdrawalfromthemold by providing draft (taper) in the direction of moldopeningor closing. • Use ribs or gussets to improve part stiffness in bending. This avoids the use of thick section to achieve the same, thereby saving on part weight, material costs, and cycle time costs. Fig -8 Life cycle of a plastic product. 6. RESULT In this Project I am developing a CAD Model by conceptual design then convert it into wireframes and surfaces using tool CATIA V5.as shown in fig 9. Fig.-9 Concept 3 Visualization Model
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1530 Fig 9 model is modified according to plastic guidelines as disused above and it is successfully modified to clear in draft angle with 0.48 degree. Fig.- 10 Concept 3 CAD Model (Clear in Draft) Fig 9 is also modified simulations for tangency with joining distance 0.001mm. In following figure is taken in a modeshading with edges withoutsmoothedges.inthismode the edges followed by tangency is not viewed. In following picture there is no sharp edges so all the required part followed by tangency. Fig- 11 concept 3 CAD Model (Follows Tangency) In Above model designingFrom VisualizationModelto Fully modified Cad model All the Criteria discussed in trade off analysis are completely followed. Like Whole Part isClear in a Draft analysis in 0.48 degree (plastic part Standard guidelines) with feature in main tolling direction and on whole part Followsa tangency throughout.Thethicknessofa dashboard I have taken is 2.5mm with no variable thickness. To improve the stiffness of a part honeycomb ribs are added to the B side of a surface. Fig -12 CAD Model (with Locating Features Follows tangency) 7. CONCLUSION Thereweremanyfactorswhichshouldbeconsidered while designing automotive IP. Apart from the producing attractive designs, this studyalso focusing on ergonomicand safety design. In this Project I am developing a CAD Model by conceptual design then convert it into wireframes and surfaces using tool CATIA V5. I am done further modification in the model by following a plastic design trim guideline and successfully modified to clear in draft and follow tangency. Many other further modifications also done overitaccording to Plastic trim industry standard. REFERENCES [1] M.D. Galer, The Application of ErgonomicsintheDesign of Automotive Displays, Butterworth & Co (Publishers) Ltd., 1984. [2] Market Report Plastics - March 2012 from http://plasticker.de/index_en.php website. [3] Lin Sun & XiaoMing Liu, Control Analysis of Production and Apparent Quality of Automobile [4] Plastic Design Guide: Part Design, Material Selection, Processing Conditions , http://www.apisolution.com/plastic-design-guide.php & Co (Publishers) Ltd., 1984. [5] Duotone. Steps used for designing packages in the packaging industry. Retrieved January 22, 2016, from http://duotone2.com/process-steps-default/process- steps-packaging-design/. [6] Automotive Product Design and Development of Car Dashboard Using Quality Function Deployment http://dx.doi.org/10.4172/2167-7670.1000136. [7] Global Automotive Plastics Market Size _ Industry Report, 2018-2025 x https://www.grandviewresearch.com/industry- analysis/automotive-plastics-market [8] Ing. Katarína Szeteiová , AUTOMOTIVE MATERIALS PLASTICS IN AUTOMOTIVE MARKETS TODAY . [9] Johanna Kaartinen A CHECKLIST FOR PLASTIC PRODUCT DESIGN, Preventing Pitfalls in a Design Process and Premature Failures of Plastic Products,
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1531 Company Supervisor: Markus Paloheimo, Sytyte Oy, University of Skode. [10] Reference Plastic Guidelines http://www.apisolution.com/plastic-design-guide.php BIOGRAPHIES Jayesh Sudhakar Sarode M-TECH (Machine Design) JTMCOE, Faizpur Dr. Atul Patil Managing Director IKSC Knowledge Bridge Pvt. Ltd. Pune Vijay Liladhar Firake Assistant Professor JTMCOE, Faizpur
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